High-Performance Industrial Furnace Transformers
Kokila Electricals manufactures a premium range of heavy-duty furnace transformers engineered specifically to endure the extreme thermal loads, high-current stresses, and intense harmonic vibrations characteristic of electric arc and induction melting operations. Built with cutting-edge technological innovations, our furnace transformers deliver exceptional power efficiency, low operating impedance, and unmatched durability in demanding metallurgical environments.
Constructed with high-grade electrolytic copper conductors and reinforced core assemblies, our oil-immersed furnace transformers conform to global manufacturing standards including IS 2026, IS 4540, IEC 60076, and environmental safety regulations. Trusted by steel plants, metal smelters, and chemical processing facilities across international markets, Kokila furnace transformers provide seamless step-down voltage control for high-current rectifier systems.
Electrostatic Earth Shielding Technology
Physical proximity between primary and secondary windings creates capacitive coupling, exposing secondary rectifier components to severe voltage surges from high-voltage grid switching. Kokila furnace transformers feature a grounded electrostatic copper shield between primary and secondary windings, effectively diverting voltage spikes to ground and extending semiconductor rectifier element life.
Rectifier Circuit Compatibility for Induction & Arc Furnaces
Our heavy-duty industrial furnace transformers are custom-designed to match specific plant rectifier circuit requirements, ensuring harmonic distortion is minimized while output efficiency is maximized. Standard circuit configurations include:
- Three-Phase Bridge Circuit: Single secondary winding optimized for standard 6-Pulse rectifier bridge systems.
- Double Star with Inter-Phase Transformer (IPT): Two star-connected secondary windings with IPT to equalize current distribution across heavy-duty rectifiers.
- 12-Pulse / 24-Pulse Multi-Phase Systems: Phase-shifted secondary windings designed to suppress low-order harmonics in high-power furnace installations.
Engineering & Technical Highlights
Smelting and induction operations generate severe electrical stress. Kokila engineers integrate advanced structural and thermal countermeasures to ensure uninterrupted continuous performance:
- Low Current Density Winding: Utilizes oversized electrolytic copper tubing to restrict thermal runaway caused by heavy harmonic currents.
- Reduced Core Flux Density: Prevents core saturation and minimizes eddy current losses under non-linear harmonic flux conditions.
- Reinforced Short-Circuit Resistance: Rigid mechanical clamping and braced coil supports absorb violent magnetic forces during arc furnace short-circuit events.
- Advanced Cooling Options: Available with ONAN, ONAF, OFWF (Oil Forced Water Forced), and OFAF forced cooling systems tailored to plant operational intensity.
Technical Specifications Parameter
| Technical Parameter | Specification Range |
|---|---|
| Power Rating Capacity | Up to 50 MVA (Custom Ratings Available) |
| Primary Voltage Class | 11 kV / 22 kV / 33 kV / 66 kV (50 Hz / 60 Hz) |
| Secondary Voltage Output | Custom Low Voltage, High Current Output Taps |
| Winding Material | 100% Oxygen-Free High-Conductivity Copper |
| Insulation & Cooling | Class A Mineral Oil / ONAN, ONAF, OFWF Cooling |
| Surge Protection | Grounded Electrostatic Copper Shielding |
| Compliance Standards | IEC 60076, IS 2026, IS 4540, IEEE C57.18.10 |
Applications & Industrial Operating Sectors
Our furnace transformers power heavy industrial metallurgical processes around the world, providing reliable continuous operation under high thermal stress:
- Electric Arc Furnaces (EAF): Steel manufacturing and scrap metal recycling facilities.
- Induction Melting Furnaces: Ferrous and non-ferrous metal foundries (Copper, Aluminum, Brass).
- Submerged Arc Furnaces (SAF): Ferro-alloy production, silicon smelting, and calcium carbide plants.
- Electrochemical Rectifiers: High-current electrolysis and chemical extraction operations.
Frequently Asked Questions (FAQ)
How do electrostatic shields protect furnace transformers?
Ground-connected electrostatic copper shields positioned between primary and secondary windings suppress capacitive coupling, preventing high-voltage primary surges from damaging secondary-side rectifier semiconductors.
What makes Kokila furnace transformers resistant to harmonic heating?
We engineered our transformers with reduced electrical current and flux densities, combined with specialized core laminations, effectively reducing stray losses and heat buildup caused by non-linear furnace load harmonics.
Can Kokila manufacture custom voltage tap ranges for specific furnace models?
Yes, our engineering team customizes primary tap changers (On-Load Tap Changers or Off-Circuit Tap Changers) to deliver precise low-voltage, high-amperage output matching your exact furnace design.
Request Technical Specifications & Global Quotation
Partner with Kokila Electricals for custom-engineered industrial furnace transformers. Connect with our engineering team to review line diagrams and obtain factory-direct pricing.
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