Komprehensibong Solusyon sa Mataas na Epektibidad nga Furnace Transformer
Ⅰ. Puntos Central nga Dolor ug Pagpakita sa Solusyon
Ang mga butang sa furnace nagkonsumo og 20%-40% sa total nga industriyal nga energia, uban ang tradisyonal nga transformers nagpakita og kasagaran kaubos nga core/copper losses ug mahimong pagkawas sa epektividad bahin sa pagbag-o sa load. Kini nga solusyon nagpadako og material innovation, structural optimization, ug intelligent control para sa tanang scenario nga pag-save sa energia.
II. Key Technology Implementation
- Ultra-Low Loss Core Design
• Nagamit og 0.23mm thick 30ZH120 high-permeability cold-rolled silicon steel (>1.9T flux density), naghulagway og 45% ka pagbawas sa eddy current losses.
• Stepped stacking + vacuum epoxy impregnation minimizes magnetic circuit air gaps. No-load loss ≤0.25% rated capacity. - Dynamic Copper Loss Suppression
•Transposed conductors + foil-wound coil structure enables:
✓ Intelligent sectional conductor cross-sections
✓ Added shielding windings in high-frequency zones
✓ 30% reduction in resistive losses
• Forced-directed oil circulation maintains coil hotspot temperature <65°C. - Intelligent Thermoregulation System
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Control Module |
Functionality |
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PID adaptive algorithm |
Real-time output voltage adjustment (±1% accuracy) based on electrode current and furnace temperature profiles (0.1°C resolution) |
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Off-peak power prediction |
Automatically boosts melting efficiency during low-tariff periods using grid load curves |
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Fault fuse protection |
Tiered alarms for coil ΔT>15°C or oil>75°C; power cutoff within 0.5 seconds |
III. Quantified Energy Savings
vs. conventional furnace transformers:
• 40% lower core losses: Annual reactive power savings ≈220,000 kWh
• 35% lower copper losses: Full-load efficiency consistently >99.2%
• 8%-12% reduction in power consumption per tonne of steel: Saves ≥¥1.5 million annually for a 50t EAF
IV. Typical Applications
- Steelmaking: Matches 20-150t EAFs handling frequent impact loads
- Non-ferrous metal casting: Suitable for Cu/Al smelting with low-voltage/high-current demands
- Special alloy production: Supports 0.5-35kV wide-range voltage regulation for precision temperature control
V. Full Lifecycle Services
• Warranty: 10-year operational lifecycle, 72-hour failure response
• Efficiency monitoring: IoT-enabled energy management platform with real-time loss data uploads
• Retrofit support: Energy-saving upgrades for existing furnace transformers (≤15-day installation cycle)
