As the core supporting link of basic industries such as steel and chemicals, coking engineering undertakes the production tasks of key products such as coke, gas, and tar, and its stable operation is highly dependent on reliable and efficient power supply systems. From coke oven heating, dry quenching cooling to gas purification and waste heat power generation, the application of the power supply system runs through the whole chain of coking engineering, not only providing stable power for the whole process of production equipment, but also directly related to production safety, energy efficiency level and operational efficiency, becoming a key support for promoting the green and intelligent transformation of the industry. An unexpected power outage not only means production interruption and equipment damage, but can also lead to safety accidents and huge economic losses.

 Customer case study: Power supply system project of a steel base in Xinjiang       

This base is a regional industrial layout of a large steel group, located at an altitude of about 1336 meters in southern Xinjiang, China, with an average annual temperature of 7.6 °C, a maximum temperature of 33.2 °C, a minimum temperature of -32 °C, a huge temperature difference, and a relative humidity of 81.6% in winter. As the "green engine" of the modern steel industry, its gas purification and dry quenching system is not only the key to environmental protection, but also the "heart" of the stable operation of the whole plant. Under extreme climatic conditions, the reliability of the power supply system directly determines the continuity and production safety of the gas purification and dry quenching processes.

The dry quenching system is the core link of energy conservation in coking engineering, which realizes waste heat recovery by cooling red coke through inert gas, and its operation interruption will lead to major safety accidents such as red coke accumulation and boiler overpressure, so the redundancy and rapid response ability of the power supply system are extremely high.

Solution

In response to the above challenges, the project team deployed a set of deeply customized AC and DC power solutions for the gas purification electrical room and the dry quenching electrical room, and the core of our solution is "high reliability, strong adaptability, and intelligence":

01 Customized hardware configuration, not afraid of severe cold and high altitude  

Core configuration: It adopts 120Ah/DC220V specification and is equipped with dual power inlet automatic switching function to ensure the double guarantee of AC input. Severe cold adaptation: The original German Sunshine (Sonnenberg) maintenance-free sealed lead-acid battery is selected. The battery is known for its excellent deep cycling capabilities and wide temperature range adaptability, maintaining stable discharge performance even at extremely low temperatures of -32°C, ensuring the safety of power supply in winter. High-altitude design: The electrical clearance and creepage distance inside the system are optimized according to the environment of 1336 meters above sea level, and the insulation strength has passed the withstand voltage test of AC 2500V/1 minute, ensuring safe operation in thin air.

02 High-frequency switching technology to provide "pure" power   

The system adopts advanced pulse-width modulation (PWM) high-frequency switching power supply technology and modular design (N+1 backup). Excellent indicators: voltage regulation accuracy ≤±0.5%, ripple coefficient ≤±0.1%. This "pure" DC power effectively avoids the interference of voltage fluctuations on precision relay protection devices and control signals, and prevents misoperation or rejection.

 03 All-round intelligent monitoring to achieve "unattended"    

Equipped with a 10.4-inch color touch LCD display, full Chinese menu, intuitive and convenient operation. Integrated microcomputer battery automatic inspection and insulation inspection functions. The system can monitor the voltage, internal resistance and the status of the entire group of each battery in real time, and has a temperature compensation function to automatically adjust the charging parameters to extend the battery life. With perfect sound and light alarm and "four remotes" (telemetry, remote signal, remote control, remote adjustment) functions, it can be easily connected to the factory's comprehensive automation system to achieve remote monitoring and management.

Project effectiveness and customer value

At present, these two AC and DC power supply systems have been operating stably at the site of the coking project in southern Xinjiang.

● Stable operation: Even in the extremely cold weather of -30°C in southern Xinjiang in winter, the system can still stably output a voltage of DC220V, and the instantaneous current of the closing bus can reach 360A, which fully meets the closing needs of 10kV switchgear.

● Safety-free: The intelligent monitoring system has repeatedly issued timely warnings when the battery voltage is abnormal or the insulation drops, helping operation and maintenance personnel eliminate hidden dangers in the bud, and building a solid power safety defense line for the two high-risk process links of dry quenching and gas purification.

● Easy maintenance: The modular design makes maintenance extremely simple, and the charging module supports live hot-swapping, greatly reducing the mean maintenance time (MTTR).

The successful delivery and application of the AC and DC power supply system for the gas purification and dry quenching electrical room is a practice of high-standard, intelligent and standardized power supply solutions for the specific industrial environment needs. The project not only meets the requirements of stable operation under extreme natural conditions, but also provides a strong boost to the long-term safe operation of users through intelligent management, demonstrating the core value of key industrial power supply equipment in modern iron and steel enterprises.