In the metal casting and heat treatment industry, a wide range of heavy-duty equipment such as resistance furnaces, heat treatment furnaces, electric arc furnaces, and intermediate frequency furnaces are widely used for heating and heat preservation. In addition, frequency converters, water pumps, and motors are essential for cooling systems and assembly lines.

These devices, however, are nonlinear loads, which inevitably generate significant harmonics that negatively impact production. The main problems include:

• Capacitor Oscillation: Capacitor compensators trip during switching and cannot be reliably put into service.

• Process Instability: Heating performance of heat treatment devices fails to meet expected standards, reducing process efficiency and doubling heating time.

• Equipment Damage: Sensitive measurement and control devices are exposed to failures due to harmonic interference.

• Transformer Risk: Increased stress on transformers creates serious safety hazards in power supply systems.

Adopted Solution

To solve these problems, Elcosine Power provided an advanced comprehensive power quality solution, including:

• CJ Series Switching Capacitor Contactors
  Designed to withstand high temperature environments and large voltage fluctuations, with low power consumption for reliable capacitor switching.

• CKSG Filter Reactors + Filter Capacitors
  Suppress harmonic resonance and ensure smooth, stable, and reliable operation of the compensation system.

• Active Power Filter (APF) Devices
  Effectively eliminate harmonics, bringing distortion levels in line with national standards.

Achieved Results

• Power Factor Correction: Improved to meet system requirements, ensuring energy efficiency.

• Harmonic Suppression: Harmonics filtered effectively, protecting transformers and sensitive equipment.

• Safe Operations: Reduced hidden risks and improved reliability of transformers and key electrical components.

• Quality Improvement: Stable power supply increased the qualified production rate, ensuring better consistency in manufacturing.

Through Elcosine Power’s solutions, metal casting and heat treatment enterprises achieve safe, stable, and efficient operations, while reducing downtime and protecting critical assets.