Comprehensive High-Efficiency Furnace Transformer Solution
Ⅰ. Core Pain Points & Solution Approach
Furnace equipment consumes 20%-40% of total industrial energy, with traditional transformers exhibiting excessively high core/copper losses and significant efficiency degradation under load fluctuations. This solution integrates material innovation, structural optimization, and intelligent control for all-scenario energy savings.
II. Key Technology Implementation
- Ultra-Low Loss Core Design
• Employs 0.23mm thick 30ZH120 high-permeability cold-rolled silicon steel (>1.9T flux density), reducing eddy current losses by 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)
