Dynamic Reactive Power Compensation Solution for Electric Furnace Transformers

08/09/2025

Dynamic Reactive Power Compensation Solution for Electric Furnace Transformers

Electric furnaces (particularly arc furnaces and submerged arc furnaces) exhibit significant ​shock load characteristics​ during smelting processes, causing ​severe power factor fluctuations (typically between 0.6 and 0.8). This not only leads to grid voltage fluctuations, flicker, and harmonic pollution but also increases line losses and reduces grid power supply efficiency.

To address this challenge, this solution employs ​high-performance dynamic reactive power compensation devices (such as SVC/TSC or SVG), integrated with coordinated control of the electric furnace transformer:

  1. Real-time Monitoring & Dynamic Response: High-speed sensors continuously capture system parameters (power factor, voltage, current, etc.). Using advanced control algorithms (e.g., instantaneous reactive power theory), data analysis is completed within ​10~20ms, triggering compensation commands.
  2. Precise Reactive Power Regulation: Automatic switching of capacitor banks/reactors (TSC/TCR mode) or rapid IGBT-based reactive power output adjustment (SVG mode) responds to load changes. This dynamically stabilizes the power factor ​above 0.92​ and suppresses voltage flicker to within ​IEEE 519 standard limits.
  3. Synergistic Efficiency Optimization: The compensation device and transformer form a closed-loop control system, reducing transformer copper and iron losses, minimizing grid reactive power flow transmission, and collectively lowering ​line losses by 6%~15%.

Value Realization:

  • Enhanced Grid Stability: Reduces voltage fluctuations, preventing tripping of surrounding equipment during furnace operation.
  • Compliance with Power Quality Standards: Meets stringent industrial requirements (THD ≤ 5%, flicker Pst ≤ 1.0).
  • Reduced Operating Costs: Avoids utility power factor adjustment penalties and extends transformer lifespan.
  • Compatible Expansion Capability: Supports integration with Active Power Filters (APF) for combined "Reactive Power + Harmonic" management.

Typical Application Scenarios:
► Steelmaking Arc Furnaces ► Ferroalloy Submerged Arc Furnaces ► Si-Ca-Ba Smelting Furnaces ► Carbon Electrode Baking Furnaces

​Solution Advantage Description:

  1. Core Technology
    Utilizes fully digital control chips (e.g., DSP+FPGA architecture) for millisecond-level response, far exceeding the compensation speed (seconds) of traditional contactor switching. This accommodates the abrupt load changes characteristic of electric furnaces.
  2. Cost Optimization
    Designed for medium-voltage grids (6~35kV). Δ/Y-connected multi-stage capacitor bank configurations reduce per-unit capacity costs. Coordinated with transformer tap changers to minimize compensation device capacity requirements, lowering investment costs by over ​30%.
  3. Reliability Assurance
    Features built-in harmonic protection algorithms (auto-avoidance of 5th, 7th, 11th harmonic resonance points), temperature monitoring, and rapid arc-flash bypass protection. Achieves an equipment ​MTBF (Mean Time Between Failures) of 100,000 hours.
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