Komprehensibong Solusyon para sa Mataas na Epektibidad na Furnace Transformer
Ⅰ. Pangunahing mga Punto ng Sakit at Pagpapatupad ng Solusyon
Ang mga kagamitan sa pugon ay nakokonsumo ng 20%-40% ng kabuuang enerhiya ng industriya, kung saan ang mga tradisyonal na transformer ay may napakataas na core/copper losses at malaking pagbawas ng epektividad sa ilalim ng pagbabago ng load. Ang solusyong ito ay nagbibigay ng inobasyon sa materyales, optimisasyon ng estruktura, at intelligent control para sa lahat ng scenario ng pag-iipon ng enerhiya.
II. Pagpapatupad ng Pangunahing Teknolohiya
- Pagdidisenyo ng Ultra-Low Loss Core
• Gumagamit ng 0.23mm thick 30ZH120 high-permeability cold-rolled silicon steel (>1.9T flux density), na nagpapababa ng eddy current losses ng 45%.
• 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)
