Solution description

The mining and metallurgy industry is a fundamental sector of the national economy and one of the areas with concentrated electricity consumption. Its load types are extremely diverse and have high power density. The mining sector mainly includes: mine hoists, blowers, drainage pumps, air compressors, crushers, ball mills, conveyor belt conveyors, mining equipment, and other large motor-type inductive loads; The metallurgy sector mainly includes: electric arc furnaces, mine heating furnaces, medium-frequency induction furnaces, rolling mills (AC/DC/AC variable frequency rolling mills and AC/AC variable frequency rolling mills), roller load loads, various rectifier electrolysis equipment, welding machines, resistance furnaces, heat treatment furnaces, molten steel transport vehicles, oxygen lance lifting systems, and more. Among these equipment, motor loads account for the vast majority of total electricity demand in the mining and metallurgy industry, with generally low power factor, generally between 0.75~0.85, and require absorbing a large amount of reactive current during operation. Meanwhile, a large number of nonlinear devices such as frequency converters, medium-frequency furnaces, electric arc furnaces, and rolling mill rectifiers generate abundant harmonic currents during operation. In the metallurgical industry, harmonic currents are generally 5th, 7th, 11th, and 13th orders; if the system contains many single-phase harmonic sources, 3rd harmonics are also included. In the mining industry, the startup of large equipment in mines and the operation of variable frequency equipment also inject a large amount of harmonics into the power grid. Harmonic pollution can cause capacitors to trip immediately after closing and cannot be put into operation, leading to severe overheating of transformers and power supply lines, frequent blowing of fuses, and even serious consequences such as computer malfunction, control system failure, relay protection malfunctions, and capacitor explosions. The overlapping of harmonic and reactive power issues seriously threatens the safe and stable operation of power distribution systems and normal production order in mining and metallurgical enterprises. 

Recommended plan

In low-voltage distribution systems of mining and metallurgy enterprises, an IVL-RCS static filtering compensation module is installed. This assembly consists of a filter capacitor and a filter reactor, specifically designed for reactive power compensation and filtering in harmonic pollution distribution systems. Among them, the RCS series filter compensation module, with a reactance of 7%, has a tuning frequency of 189Hz, providing reliable reactive power compensation while effectively suppressing harmonic pollution of 5 or more harmonics, suitable for metallurgical industrial scenarios where frequency converters and mill rectifiers are the main harmonic sources; The RCS series filter compensation module, with a reactance of 14%, has a tuning frequency of 134Hz, effectively suppressing 3rd and more harmonic pollution, suitable for working conditions where 3rd harmonic interference is prominent, such as arc furnaces and welding machines. Based on the actual harmonic conditions in the mining and metallurgical power systems, a hybrid configuration of 7% reactance rate and 14% reactance module can be adopted to effectively suppress harmonics across the entire frequency band. This module uses high-voltage grade low-voltage filter capacitors and H-class insulated, high-linearity, strong overload capacity, and highly reliable filter reactors. To address severe reactive power fluctuations caused by impact loads such as mine hoists, arc furnaces, and rolling mills, IVL-APF active filters or dynamic reactive power compensation devices can be further configured to work in coordination with IVL-RCS static filter compensation modules to achieve comprehensive management of dynamic reactive power compensation and broadband harmonic filtering. Combined with our company's production of high-voltage switchgear, low-voltage switchgear, box-type substations, cable branch boxes, switches, ring control cabinets, gas fillers, environmental protection cabinets, prefabricated cabins, and other complete sets of power equipment, we provide mining and metallurgical enterprises with full-chain power quality solutions from high-voltage incoming lines to low-voltage distribution in workshops, ensuring the safe, stable, and efficient operation of distribution systems. 

Solution benefits

Significantly increase the power factor of distribution systems in mining and metallurgical enterprises to above 0.95, avoiding power factor fines caused by substandard power factor and directly reducing monthly electricity expenses; Reduce line and transformer losses, decrease energy waste, and improve power supply economics; Filter harmonic currents and suppress harmonic amplification, effectively protect key distribution equipment such as transformers, capacitors, cables, and motors, and lower equipment failure rates; Ensure the reliable operation of mine hoists, ventilators, drainage pumps, and other safety production equipment, avoiding safety hazards caused by power quality issues; Ensure stable operation of metallurgical production equipment such as rolling mills, electric arc furnaces, and medium-frequency furnaces, avoiding issues such as extended heating speed and process control failures caused by harmonic interference; Extend equipment service life and reduce maintenance and replacement costs; Eliminate system resonance hazards and improve power supply reliability. The solution offers both energy saving, consumption reduction, and quality and efficiency improvement, providing a solid power guarantee for mining and metallurgy enterprises to achieve safe production and green manufacturing.