Application and energy-saving effect of medium-voltage frequency converters in the metallurgical industry
2026-04-06 06:37:20··#1
Rockwell Automation is a leading brand in the automation industry, with medium-voltage frequency converters as its flagship product. The company's products are divided into two different cooling modes: traditional air-cooled converters with power ratings below 4300kW, and water-cooled converters for higher power ratings. Regardless of the type, they are all high-voltage frequency converters with the simplest structure, maturely applicable to various working conditions. The entire converter does not require a step-up transformer, has only three secondary windings, and the total number of power components (including the rectifier and inverter sides) is only 36. Furthermore, within its 20-year lifespan, no component requires periodic or irregular replacement. Therefore, the equipment boasts exceptional reliability, a key strength of our products. Different companies position their products differently in the market, and their technologies have varying characteristics; it's unrealistic for any single product to be perfect in every aspect. No technology is flawless; many technologies are interdependent. For example, simplifying a product often requires larger component sizes and higher development costs. Therefore, even among high-voltage frequency converters, different products can have significantly different prices. This is closely related to the core technology inside the frequency converter. Therefore, when choosing a frequency converter, users should not only consider the price but also its internal core components. The metallurgical industry is currently the sector where Rockwell Automation holds the largest market share in China. The metallurgical industry is characterized by: large-scale production; relatively dense resources; and relatively advanced automation levels. The industry's current situation is characterized by high energy consumption, severe pollution, and high requirements for automation levels. my country's metallurgical industry is transitioning from a situation of supply falling short of demand to one of supply exceeding demand, with manufacturers continuously consolidating. For manufacturers, effectively controlling production costs is an urgent issue. In response to the national call for energy conservation and emission reduction, different departments and associations have formulated corresponding policies. By the end of 2010, my country's energy consumption per unit of GDP was to be reduced by 20% compared to the end of the "10th Five-Year Plan" period. In achieving these goals, the application of high-voltage frequency converters is a good choice. Relevant data shows that in industries such as mining, steel rolling, ironmaking, and steelmaking, there are many loads of fans and pumps. The total installed capacity is 19710MW. Currently, the number of users actually using high-voltage frequency converters is only the tip of the iceberg. When discussing the metallurgical industry, let's briefly look at a few process applications of high-voltage frequency converters. For example, consider the dust removal fans in blast furnaces. Because a large amount of smoke and dust is generated during iron tapping, the dust removal fans need to instantly increase airflow to remove waste gas throughout the smelting process, reducing environmental pollution and meeting process requirements. Previously, dust removal fans adjusted airflow using baffles; now, frequency converters are used for speed control, saving energy lost on the baffles. Similarly, dust removal fans in steel plants serve a similar purpose. Furthermore, equipment such as blast furnace sand removal pumps in ironmaking plants experience significant load variations during smelting. In such applications, high-voltage frequency converters, utilizing the characteristics of centrifugal loads, can achieve energy savings and reduce consumption at lower speeds. Of course, achieving optimal performance with the same frequency converter is also crucial for users. We need to place the frequency converter in its ideal power range and select the most suitable equipment for use to maximize its effectiveness. Rockwell Automation has a substantial user base in the metallurgical industry. The loads in the metallurgical industry differ significantly from those in other industries. Products in this sector often handle high-power loads. Rockwell's main market share lies in these high-voltage, high-power inverter applications. This is because our equipment uses SGCT power components, with a single unit withstand voltage of 6500V and a rated current of 1500A, making them the highest capacity power devices on the market. Therefore, in large-scale equipment, we only require 36 power components, without increasing the number. The reason for emphasizing the low number of power components required is that every component has potential points of failure; only by making the equipment as simple as possible can safety and reliability be guaranteed. Besides the metallurgical industry, our inverters are widely used in the power, petrochemical, and cement industries. AB began promoting medium-voltage inverters in the Chinese market around 2000. However, in just five or six years, our sales have exceeded 430 units, achieving high market recognition.