Zhejiang Hongyan Electric Co., Ltd. 
ENGINEERED SOLUTION
Steel & Metallurgy
Power factor correction, harmonic mitigation and voltage support for electric arc furnaces, rolling mills, cranes and high-load metallurgical production lines.
HYFCKRL Series Ferroalloy Submerged Arc Furnace Harmonic Filtering & Reactive Compensation System
The HYFCKRL series is designed specifically for submerged arc furnaces (SAF), also known as mineral heat furnaces or electric arc resistance furnaces. In these systems, the electrodes are buried deep within the charge layer, forming an arc and generating heat through material resistance. This thermal and electrical process is essential for smelting various alloys and chemical materials.
Product Introduction
The HYFCKRL series is designed specifically for submerged arc furnaces (SAF), also known as mineral heat furnaces or electric arc resistance furnaces. In these systems, the electrodes are buried deep within the charge layer, forming an arc and generating heat through material resistance. This thermal and electrical process is essential for smelting various alloys and chemical materials.
Typical applications include the production of ferroalloys such as ferro-silicon, ferro-manganese, ferro-chrome, ferro-tungsten, and silicon-manganese alloys, as well as calcium carbide, nickel matte, copper matte, and phosphorus-related smelting processes. Due to the heavy non-linear loads and arc-type operating characteristics, SAF systems introduce significant harmonics, voltage fluctuations, and power factor reduction to the grid. The HYFCKRL filtering and compensation system is engineered to address these issues, ensuring stable furnace performance and improved energy efficiency.
Product Features
✔ Dedicated Harmonic Filtering
- Configured according to the SAF’s characteristic harmonic spectrum (typically 2nd, 3rd, 5th, 7th, 11th, 13th).
- Wide-band or multi-branch tuned filtering circuits absorb harmonic currents effectively.
- Reduces voltage distortion and protects power system stability.
✔ Reactive Power Compensation
- Compensates dynamic reactive demand caused by arc fluctuations.
- Improves power factor significantly, stabilizing furnace transformer operation.
- Reduces network losses and enhances transformer loading efficiency.
✔ Enhanced System Stability
- Mitigates flicker caused by arc voltage fluctuations.
- Improves furnace power utilization, increasing output and reducing smelting time.
- Protects motors, transformers, cables, and sensitive equipment from harmonic impacts.
✔ High Reliability
- Heavy-duty filter reactors, capacitors, and dedicated switching components ensure long-term operation.
- All internal components comply with industrial-grade insulation, thermal, and vibration standards.
- Rugged design adapted to metallurgical environments with high dust, heat, and mechanical stress.
✔ Intelligent Control
- Real-time monitoring of voltage, current, harmonics, and reactive power.
- Automatic switching of filter branches according to furnace operating conditions.
- Stable compensation with seamless transitions, ensuring continuous protection.
Technical Specifications
| Category | Main Raw Materials | Final Product | Reaction Temperature (°C) | Power Consumption (kWh/t) |
|---|---|---|---|---|
| Ferrosilicon Furnace (45% FeSi, 75% FeSi, 99% FeSi) | Silica, Scrap Iron | Ferrosilicon | 1530–1750 | 2100–5500 |
| Industrial Silicon Furnace | Silica, Petroleum Coke | Metallurgical Silicon | 1620–2150 | 1200–13800 |
| Silicon Manganese Furnace | Manganese Ore, Scrap Iron, Coke | Si-Mn Alloy | 1510–1400 | 2400–4000 |
| Chromium Furnace | Chrome Ore, Silica, Coke | Ferrochrome | 1620–1760 | 3200–6000 |
| Calcium Furnace | Fluorite, Coke | Calcium | 2400–2900 | 3200–6000 |
| Silicon Calcium Furnace | Ferrosilicon, Silica, Coke | Si-Ca Alloy | 1650–1750 | 3500–6500 |
| Silicon Magnesium Furnace | Magnesium Ore, Silica, Scrap Iron | Si-Mg Alloy | 1350–1400 | 3500–4000 |
| Steelmaking Electric Arc Furnace | Iron Ore, Coke | Crude Steel | 1550–1600 | 1800–2500 |
| Graphite Electrode Furnace | Petroleum Coke, Anthracite | Graphite Electrode | 1950–2000 | 1900–3000 |
| Calcium Carbide Furnace | Limestone, Coke | Calcium Carbide | 1830–2500 | 20000 |
Operating Conditions
- Installation Location: Indoor or outdoor cabinet-type installation
- Ambient Temperature: –15°C to +45°C
- Altitude: ≤ 2000 m
- Relative Humidity: ≤ 95% (non-condensing)
- Environmental Requirements: Non-corrosive gases, no conductive dust, no flammable vapors
Core Advantages
● Increased Smelting Efficiency
- Efficient filtering reduces harmonic pollution and stabilizes transformer voltage.
- Improved arc stability enhances melting speed and output quality.
● Lower Operating Costs
- Reduces equipment overheating, insulation aging, and cable losses.
- Extends the service life of electrodes, transformers, and power components.
● Grid-Friendly Operation
- Minimizes flicker and voltage dips caused by the furnace’s heavy non-linear load.
- Ensures compliance with national power quality limits.
● Modular Cabinet Structure
- Cabinets include capacitors, reactors, breakers, disconnectors, control units, and protection modules.
- Efficient heat dissipation ensures stable operation in extreme industrial environments.
Compliance Standards
The system meets relevant national standards, including:
- GB/T 14549-93 – Power Quality: Harmonics Limits
- GB 50227-95 – Shunt Capacitor Installation
- GB 7251.12 – Low-Voltage Switchgear
- GB/T 15576 – Reactive Power Compensation Devices
- IEC Applicable Standards (upon request)
Related Products
Send Inquiry
FROM EQUIPMENT TO APPLICATION
See where this equipment fits in the system
Connect product selection with the network problem it addresses and review comparable project conditions before preparing an enquiry.
Relevant Solutions
All Solutions
Application Cases
All Cases
PROJECT REFERENCE
High Voltage Compensation Unit
High-voltage power factor correction configured for an outdoor industrial distribution system with a target power factor above 0.95.
PROJECT REFERENCE
Transformer Cooling & Efficiency Project
Coordinated power-quality and thermal operating measures for a large-capacity transformer serving a variable industrial load.