Compared to conventional transformers, a 2500kVA amorphous alloy transformer can save 21,000 kWh of electricity annually. Taking 50 units as an example, this translates to an annual electricity savings of 1.05 million kWh and a reduction in coal consumption by 420 tons. Additionally, it contributes to a reduction in carbon dioxide emissions by approximately 1,050 tons.
Introduction to Amorphous Alloy Transformers
Amorphous alloy transformers, developed in the 1970s, are a new type of electrical transformer that utilizes amorphous alloy instead of silicon steel as the core material. They exhibit a significant reduction in no-load losses, around 70%-80% lower than silicon steel core transformers, and a drop of approximately 85% in no-load current. These transformers are currently among the most energy-efficient distribution transformers available. They are suitable for applications where distribution efficiency is low, and there are stringent requirements for fire resistance, such as rural electrical grids, high-rise buildings, commercial centers, subways, airports, stations, industrial and mining enterprises, and power plants.
Amorphous Alloy Ribbon
Amorphous alloy ribbon is created by synthesizing elements like iron, cobalt, carbon, silicon, and boron in specific proportions. It is then rapidly cooled under high-speed spinning at 10°C/S during high-temperature melting. This process eliminates distinct crystalline boundaries in the metal, resulting in an irregular amorphous structure.
Unique Amorphous Alloy Design, Equipment, and Manufacturing Process
Design: Adopt advanced electromagnetic design optimization software to improve the accuracy and speed of amorphous alloy dry-type transformer design, and realize design automation and optimization. Powerful simulation analysis capabilities, for each series of products, through simulation analysis of flow field, temperature field, leakage magnetic field, short-circuit force, etc., to ensure product safety and reliability.
Iron Core: Using high-quality amorphous strip materials to create Three-Phase Three-Limb cores, subjected to annealing under the influence of a direct current magnetic field to achieve outstanding characteristics of low iron loss and low excitation current. The core surface is coated with a special resin to prevent moisture and corrosion. The core structure is simple, with high mechanical strength, resistance to high-order harmonics, and 70% to 80% lower iron loss compared to conventional products.
Low Voltage Foil Winding Coils: Employ imported high-quality copper foil and H-class insulation materials wound on molded insulation cylinders. Layer insulation is made of NOMEX paper, and VPI vacuum pressure impregnation solidifies it into a sturdy whole. The upper and lower ends are sealed with resin. The copper bars and foils are welded using specialized equipment. These coils exhibit high mechanical strength, strong short-circuit resistance, and excellent resistance to dust, moisture, and salt spray.
High Voltage Winding Coils: Using a multi-layer segmented cylindrical design with a longitudinal multi-channel structure. They exhibit strong resistance to heat and shock, as well as excellent impulse withstand capability. The conductor is composed of NOMEX paper-wrapped flat copper wire, with NOMEX paper used for layer insulation and H-class material for end insulation. After VPI vacuum pressure impregnation, the coils undergo high-temperature baking for curing. The upper and lower ends are sealed with resin, ensuring good heat dissipation and preventing cracking.
Assembly: Utilize the coil as the load-bearing main body, which is supported on a separate winding system and fixed by compression. The iron core employs a suspended structure so that the iron core is not under pressure, which reduces the influence of radial shrinkage and expansion on the iron core when the transformer is short-circuited. The overlapping part of the iron core adopts a special glue end-sealing process to ensure the minimum force on the iron core.
Our production base covers an area of more than 600 acres (40 hectares) with extensive facilities and a total construction area of 180,000 square meters. We have a professional team of more than 1,000 employees. We have advanced transformer production and testing equipment here to ensure that we provide customers with high-quality power transformer products.
We boast an array of cutting-edge equipment representing a high standard within the industry, including a complete set of shearing machines, fully automated winding machines, robot-operated stacking machines, the Hedrch Vacuum Casting Equipment, vacuum impregnation systems, air cushion transport vehicles, a fully enclosed production workshop with a cleanliness level of 100,000, 20-ton vertical winding machines, 10-ton horizontal winding machines, coal-oil gas phase drying equipment, and a 200-ton overhead crane. We adopt the latest technology and processes to ensure that our products comply with international standards and customer needs.
We have a strong production capacity of 30 million kVA power transformers per year. This means we can cater to all sizes and types of power transformer needs, from small applications to large energy projects. No matter what specifications our customers require, we deliver them on time and support them with high quality and reliability.
