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The arc furnaces can be found in the Ceramic production, in the manufacture of Quartz Crucible for the pulling of semiconductor and PV silicon. A digital and dynamic current source with high system efficiency, high power factor (PF) and low harmonic distortion (THD) without electro-mechanically adjustable transformers. The power supply for an arc furnace with the typical strong nonlinear load curve requires a fast dynamic current source.
The arc furnaces can be found in the Ceramic production, in the manufacture of Quartz Crucible for the pulling of semiconductor and PV silicon. A digital and dynamic current source with high system efficiency, high power factor (PF) and low harmonic distortion (THD) without electro-mechanically adjustable transformers. The power supply for an arc furnace with the typical strong nonlinear load curve requires a fast dynamic current source.
The arc furnaces can be found in the Ceramic production, in the manufacture of Quartz Crucible for the pulling of semiconductor and PV silicon. A digital and dynamic current source with high system efficiency, high power factor (PF) and low harmonic distortion (THD) without electro-mechanically adjustable transformers. The power supply for an arc furnace with the typical strong nonlinear load curve requires a fast dynamic current source.
Arc Furnace Power Supply Stephan Risse-Gerke, Dr.-Ing. Peter Wallmeier AEG Power Solutions GmbH, Belecke
AbstractThis contribution explains the Thyristor Power Controllers Application as power supply for arc furnaces with the advantage of a digital and dynamic current source with high system efficiency, high power factor (PF) and low harmonic distortion (THD) without electro-mechanically adjustable transformers. KeywordsPower Controllers, Arc furnace, Current source
I. INTRODUCTION The arc furnaces can be found e.g. in the Ceramic production, in the manufacture of Quartz Crucible for the pulling of semiconductor and PV silicon with the Czochralski- Procedure. The typical industry plant electrical diagram is shown on Fig.1. Every power supply, an AEG PS Thyrobox TM - F, is powered by a medium voltage transformer and has a pure capacitive Var compensation on the secondary side of the transformer.
Fig.1. A typical system configuration. One power supply feeds two arc furnaces alternately with a maximum output current up to 2500Amps and a maximum output voltage up to 400V. The operating area with the maximum voltage and current ratings for the load is shown on Fig.2. The power supply has an interlock function for the two arc furnaces.
Fig.2. Operating area Thyrobox-F
II. POWER SUPPLY ARCHITECTURE The demands for such a power supply are numerous. Beside a high power factor and a high efficiency, a low harmonic distortion is an important challenge. A power supply for an arc furnace with the typical strong nonlinear load curve (Fig.3), where a small voltage change results a large current change, requires a fast dynamic current source.
Fig.3. A typical strong nonlinear arc curve
One System consists of one control cabinet for the measurement acquisition and the control of the arc furnace as White Paper: Arc Furnace Power Supply
well as three power cabinets with the power electronics. An overview of the three power cabinets, the control cabinet and the Var compensation is shown on Fig.4.
Fig.4. System overview
In every power cabinet a choke is used with the four thyristors forming a fullbridge. The choke takes the role of energy storage according to
and impresses the
current in the DC pass of the fullbridge. By precise phase angle control performed by Thyro-P digital controller devices the choke current and in turn the output current is adjusted with the thyristors. The power supply takes over the function of a high dynamic current source. So the need of electromechanically adjustable transformers is eliminated by this application. This can only be achieved through a fast measured value acquisition of the electrical parameters and a fast dynamic control. The measurement of the electrical parameters and the control of the current source are effected by the Thyro-P Control Unit (Fig.5).
Fig.5. Thyro-P Control Unit The arc voltage and current values are measured with a 14 bit measurement resolution. All 3,3ms (60), the full digital control device records the current of the arc furnace and gives the pulse patterns via fiber optics to the water cooled thyristor stacks for all three phases. This guarantees a quick response to changes of the arc. III. VAR COMPENSATION With this architecture of the arc furnace power supply as high dynamic current control, sinusoidal current consumption with low harmonic distortion (THD) and flicker are possible (Fig.6).
Fig.6. Sinusoidal current consumption without compensation
The best power factor, which is defined as the ratio of the real power (P) to the apparent power (S), will be achieved at the maximum current of the Thyrobox TM -F. If the arc furnace operates not at full load, the power factor is lower as current shift relative to voltage. To increase the power factor in all operating conditions over 0.9, the use of an adjustable var compensation is necessary. The var compensation consisting of thyristor switched capacitor banks control the power factor on a maximum level by the reactive power (Q) compensation (Fig.7).
Fig.7. Phasor diagram power triangle
The reaction time is very fast by using SCR switches. A circuit diagram of the var compensation is shown on Fig.8. The var compensation system is installed on the secondary side of the medium voltage transformer.
White Paper: Arc Furnace Power Supply
Fig.8. schematic var compensation
With a Simplorer simulation model of the Thyrobox TM -F (Fig.9) the plant was simulated and the var compensation topology optimized and parameters of the built unit determined.
Fig.9. Simulation model Thyrobox TM -F with var compensation
The results of the power factor measurements on a field unit are shown on Fig.10. With the capacitive var compensation the power factor is increasing to be > 0.9. These values have been seen over a wide operating range in the field.
Fig.10. Waveforms showing low THD and phase shift between voltage and current
IV. BENEFITS A result of this architecture is the high system efficiency through the use of the lowest loss semiconductor elements thyristors. With the ability to alternately supply two electric arc furnaces with a power supply, the manufacturing capacity is increased, at the same time the space of the industry plant is optimized. Using a current source topology having sinusoidal input current an extreme high power factor of > 0.9 can be achieved by using simple capacitive var compensation. Finally the Thyrobox TM -F and the var compensation can be seen on figure 11 and 12.