Reducing Energy Consumption Through Energy Efficient Transformers For Steel Industry

This article focuses on one way which is widely ignored as a cost effective method

to reduce energy consumption in the industry, namely, the use of energy efficient transformers. Due to its unique production methodology, the steel industry often requires customized transformers.

Pacific Crest Transformers has been manufacturing all types of customized transformers for the steel industry for nearly a century now. With its extensive domain expertise, Pacific Crest Transformers has the ability to offer its clients the best of breed solutions no matter how complex the need.

The steel production process employed uses one of two processes, namely, the Basic Oxygen Furnace and the Electric Arc Furnace. Processes in steel making which consume maximum amount of energy include, sintering, coke making, iron making, EAF steel making, casting, boilers, cogeneration, reheating, rolling and finishing.

The Role of Transformers in the Steel Industry

Transformers are a vital component of the energy grid, besides other things they contribute to the efficient production and management of high-quality electricity.

Standard transformers, while under full load operate at 90% to 95% efficiency but their efficiency drops as load lightens. This is usually due to inefficiencies in the transformer's core. Losses in the core remain t he same throughout the transformer's operating range, at 100% load, the amount of comparative loss is negligible, however, at reduced loads, and a higher percentage of energy is wasted.

Average transformer loads run between 34% and 50% of the transformer's total capacity. With most of the electricity used in the US being run through transformers at lower loads, massive amounts of energy is being wasted. This issue is of special relevance to the steel industry which already has a high demand for energy.

Reducing energy consumption by adopting customized cost effective solutions like NEMA approved transformers and harnessing solar or wind energy to meet future energy needs is a good idea in the long run. Especially since alternate energy options will help steel companies avoid the uncertainty of fluctuating international fuel prices.

Role of Pacific Crest Transformers in the Steel industry

Pacific Crest Transformers (PCT) has been providing customized solutions to the steel industry since its inception in 1919. Over the last 90 years PCT has had a host of clients, both in the USA and neighboring countries.

PCT is com mitted to designing and manufacturing superior quality, custom-built and specialty transformers in the most cost-effective and responsive manner possible. The company has experience in building Padmount, Station and Secondary Unit Sub Transformers, and today specializes in environmentally friendly and efficient liquid-filled distribution transformers. PCT was propelled towards its energy efficiency initiative in its attempt to produce efficient, energy saving and environmentally sensitive transformers.

The good part about PCT is that it designs custom transformers after an elaborate consultative process with the client; the transformers are based on client specification and are designed to fit into the already existent infrastructure.

PCT custom builds various types of transformers for the steel industry, such as

" Material handling devices such as cranes, conveyor systems and augurs

" Electric arc furnaces and forges

" Manufacturing and treatment processes

" Step down transformers

" Rectifier transformers for DC furnaces

Keeping in mind that transformers in the steel industry have to operate in conditions of extreme heat, PCT pays special attention to safety and reliability of the transformers it designs. It also ensures required transformer protection equipment, such as cooling systems with redundancy is delivered and provided according to project requirements.

Conclusion

Most steel companies are under tremendous pressure to keep costs down and stay competitive and, using energy efficient transformers seems to be one good way of achieving this. Choosing the right transformer can however be a complex task, especially as the needs of a steel company can be highly customized. It is here that experienced companies like Pacific Crest Transformers can partner you through the process of identifying your needs, choosing the right transformer, customizing it to ensure you get the highest returns on your investment and facilitating its use for the longest time possible.

by: MikeD

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