Research on High-Frequency Modification Method of Industrial-Frequency Smelting Transformer Based on Parallel Connection of Multiple Windings
Under the background of “dual-carbon” strategy and global energy transition, the metallurgical industry, which accounts for 15–20% of industrial energy consumption, urgently needs to reduce the energy consumption and emission of DC power supply of electric furnaces. Aiming at the existing 400–800 V/...
Saved in:
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-08-01
|
| Series: | Energies |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1073/18/15/4196 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849407374919467008 |
|---|---|
| author | Huiqin Zhou Xiaobin Yu Wei Xu Weibo Li |
| author_facet | Huiqin Zhou Xiaobin Yu Wei Xu Weibo Li |
| author_sort | Huiqin Zhou |
| collection | DOAJ |
| description | Under the background of “dual-carbon” strategy and global energy transition, the metallurgical industry, which accounts for 15–20% of industrial energy consumption, urgently needs to reduce the energy consumption and emission of DC power supply of electric furnaces. Aiming at the existing 400–800 V/≥3000 A industrial-frequency transformer-rectifier system with low efficiency, large volume, heat dissipation difficulties and other bottlenecks, this thesis proposes and realizes a high-frequency integrated DC power supply scheme for high-power electric furnaces: high-frequency transformer core and rectifier circuit are deeply integrated, which breaks through and reduces the volume of the system by more than 40%, and significantly reduces the iron consumption; multiple cores and three windings in parallel are used for the system. The topology of multiple cores and three windings in parallel enables several independent secondary stages to share the large current of 3000 A level uniformly, eliminating the local overheating and current imbalance; the combination of high-frequency rectification and phase-shift control strategy enhances the input power factor to more than 0.95 and cuts down the grid-side harmonics remarkably. The authors have completed the design of 100 kW prototype, magneto-electric joint simulation, thermal structure coupling analysis, control algorithm development and field comparison test, and the results show that the program compared with the traditional industrial-frequency system efficiency increased by 12–15%, the system temperature rise reduced by 20 K, electrode voltage increased by 10–15%, the input power of furnace increased by 12%, and the harmonic index meets the requirements of the traditional industrial-frequency system. The results show that the efficiency of this scheme is 12–15% higher than the traditional IF system, the temperature rise in the system is 20 K lower, the voltage at the electrode end is 10–15% higher, the input power of the furnace is increased by 12%, and the harmonic indexes meet the requirements of GB/T 14549, which verifies the value of the scheme for realizing high efficiency, miniaturization, and reliable DC power supply in metallurgy. |
| format | Article |
| id | doaj-art-af23ee71dc1b4a50b96edaa35a79b459 |
| institution | Kabale University |
| issn | 1996-1073 |
| language | English |
| publishDate | 2025-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Energies |
| spelling | doaj-art-af23ee71dc1b4a50b96edaa35a79b4592025-08-20T03:36:06ZengMDPI AGEnergies1996-10732025-08-011815419610.3390/en18154196Research on High-Frequency Modification Method of Industrial-Frequency Smelting Transformer Based on Parallel Connection of Multiple WindingsHuiqin Zhou0Xiaobin Yu1Wei Xu2Weibo Li3College of Electric Power, Yinchuan Energy Institute, Yinchuan 750100, ChinaNingxia Zhongcheng Tebian Technology Co., Ltd., Yinchuan 750100, ChinaSchool of Automation, Wuhan University of Technology, Wuhan 430070, ChinaSchool of Automation, Wuhan University of Technology, Wuhan 430070, ChinaUnder the background of “dual-carbon” strategy and global energy transition, the metallurgical industry, which accounts for 15–20% of industrial energy consumption, urgently needs to reduce the energy consumption and emission of DC power supply of electric furnaces. Aiming at the existing 400–800 V/≥3000 A industrial-frequency transformer-rectifier system with low efficiency, large volume, heat dissipation difficulties and other bottlenecks, this thesis proposes and realizes a high-frequency integrated DC power supply scheme for high-power electric furnaces: high-frequency transformer core and rectifier circuit are deeply integrated, which breaks through and reduces the volume of the system by more than 40%, and significantly reduces the iron consumption; multiple cores and three windings in parallel are used for the system. The topology of multiple cores and three windings in parallel enables several independent secondary stages to share the large current of 3000 A level uniformly, eliminating the local overheating and current imbalance; the combination of high-frequency rectification and phase-shift control strategy enhances the input power factor to more than 0.95 and cuts down the grid-side harmonics remarkably. The authors have completed the design of 100 kW prototype, magneto-electric joint simulation, thermal structure coupling analysis, control algorithm development and field comparison test, and the results show that the program compared with the traditional industrial-frequency system efficiency increased by 12–15%, the system temperature rise reduced by 20 K, electrode voltage increased by 10–15%, the input power of furnace increased by 12%, and the harmonic index meets the requirements of the traditional industrial-frequency system. The results show that the efficiency of this scheme is 12–15% higher than the traditional IF system, the temperature rise in the system is 20 K lower, the voltage at the electrode end is 10–15% higher, the input power of the furnace is increased by 12%, and the harmonic indexes meet the requirements of GB/T 14549, which verifies the value of the scheme for realizing high efficiency, miniaturization, and reliable DC power supply in metallurgy.https://www.mdpi.com/1996-1073/18/15/4196smelting equipmenthigh-frequency transformersrectifier circuitshigh-frequency cores |
| spellingShingle | Huiqin Zhou Xiaobin Yu Wei Xu Weibo Li Research on High-Frequency Modification Method of Industrial-Frequency Smelting Transformer Based on Parallel Connection of Multiple Windings Energies smelting equipment high-frequency transformers rectifier circuits high-frequency cores |
| title | Research on High-Frequency Modification Method of Industrial-Frequency Smelting Transformer Based on Parallel Connection of Multiple Windings |
| title_full | Research on High-Frequency Modification Method of Industrial-Frequency Smelting Transformer Based on Parallel Connection of Multiple Windings |
| title_fullStr | Research on High-Frequency Modification Method of Industrial-Frequency Smelting Transformer Based on Parallel Connection of Multiple Windings |
| title_full_unstemmed | Research on High-Frequency Modification Method of Industrial-Frequency Smelting Transformer Based on Parallel Connection of Multiple Windings |
| title_short | Research on High-Frequency Modification Method of Industrial-Frequency Smelting Transformer Based on Parallel Connection of Multiple Windings |
| title_sort | research on high frequency modification method of industrial frequency smelting transformer based on parallel connection of multiple windings |
| topic | smelting equipment high-frequency transformers rectifier circuits high-frequency cores |
| url | https://www.mdpi.com/1996-1073/18/15/4196 |
| work_keys_str_mv | AT huiqinzhou researchonhighfrequencymodificationmethodofindustrialfrequencysmeltingtransformerbasedonparallelconnectionofmultiplewindings AT xiaobinyu researchonhighfrequencymodificationmethodofindustrialfrequencysmeltingtransformerbasedonparallelconnectionofmultiplewindings AT weixu researchonhighfrequencymodificationmethodofindustrialfrequencysmeltingtransformerbasedonparallelconnectionofmultiplewindings AT weiboli researchonhighfrequencymodificationmethodofindustrialfrequencysmeltingtransformerbasedonparallelconnectionofmultiplewindings |