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BA PTTR
Transformers
FIPTTR
Product Training
Furnace and Rectifier
Transformers

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Furnace transformers
Arc furnaces are used in the steel industry for:
Scrap iron smelting " Electric Arc Furnace
Steel refinining and alloy building "Ladle Furnace
Arc furnaces are also used for many other applications:
Glass and ceramics smelting
Manufacturing or refining of many other materials,
like ferrocrome, ferromanganese, different abrasive
material like oxides and nitrides, semiconductive
base materials, nanopowders, etc.

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"EIectric Arc Furnaces" EAF
Two different concepts: DC and AC arc furnaces
Usually rather big, the transformers 20 . 200 MVA
The very largest are always DC furnaces,
transformer feeding a rectifier
The application is demanding, short circuits,
harmonics, fast and large load fluctuations
Reactors are often needed to smoothen the
fluctuations, either in the same tank or separate
Most of these transformers belong to Legnano's or
Bad Honnef's scope

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Transformer for a DC EAF

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"LadIe Furnaces" LF
n ladle furnace the arcing occurs between the
electrodes and the molten steel
Ladle furnaces are typically 3.40 MW
They are always(?) AC furnaces.
The application is less demanding for transformer
than smelting, because the arc is rather stable.
Most of these belong to Vaasa scope

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LadIe furnace

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SmaII arc furnace transformer

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SmaII arc furnace transformer active part

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Arc furnaces for other appIications
A wide variety of materials are manufactured in the high
temperatures of arc furnaces
Typically they are oxides, nitrides and other hard
materials
Furnace power is normally not over 25 MVA, but can be
as small as a few hundred kVA
Zirconia (=zirconium oxide) nanopowder is an example
of a new exotic material (particle size 10.100 nm)
Stable arcing, transformer friendly applications

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Rectifier transformers for eIectroIysis
Electrolysis processes use high current low voltage
transformers to feed the rectifiers
The most usual electrolysis processes are the metal
refining, aluminium, copper, zinc, nickel, etc.
Chlorine is also a common eletrolytically produced stuff
Electrolysis is normally a very stable, smooth and
continuous full load for a transformer
The rectifiers are normally thyristor rectifiers
Most of the rectifier transformers supplied from Vaasa
have been for chlorine electrolysis

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Transformer for chIorine eIectroIysis rectifier

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Two rectifier transformers after testing

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Large 12-puIse rectifier transformer with doubIe water cooIer

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Large 12 puIse rectifier transformer active part

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Common features for furnace and rectifier transformers
Secondary low voltage high current causes a similar "look
Primary medium voltage
Water cooling
Wide voltage regulation range required
Often a separate autotransformer in needed for optimum voltage
regulation
ndustrial installation environment, often very demanding corrosion
protection
Losses are an important evaluation criteria, because of the high
energy consumption
Life cycle costs by maintenance and availability of service are
usually important

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Differencies between furnace and rectifier transtormers
Periodic loading with sporadic
peaks is typical
Dynamic stresses must be
observed
One three phase secondary in
AC arc furnaces
Voltage regulation by on-load
tap changer
Typical laddle furnace has
100000 on-load tap changes
per year
Continuous full loading for
long periods, years
Stresses and hot spots caused
by harmonics are challenging
Voltage regulation by off-circuit
tap changer
Tap changing needed due to
aging of the electrolysis cells,
i.e. rather seldom
Furnace transformers
Rectifier transformers

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Customers for furnace transformers
Steel manufacturers for ladle furnace transformers
An electric contractor of a new steel mill or a larger
expansion may purchase the transformer and supply it
in his project
For special arc furnaces for oxides, it seems usual that
the arc furnace manufacturer buy the transformer, and
supply it together with the furnace. Typical OEM.

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SaIes channeIs for IadIe furnace transformers
All steel mills in the world are customers to ABB already
The local ABB in each country knows them and most
probably is selling some ABB products to each one.
ABB ndustrial Transformers may have experience or
reference in transformer sales
We should aim for a regular and short sales channel:
ABB Vaasa Local ABB Steel Mill

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SaIes channeIs for oxide arc furnaces
Only OEM customer known is Whiting nc. in Canada
We made a couple of quotation without success, and the
contact is now inactive
An inquiry for many units of very small arc furnace
transformers was once received from California. We
presented some clarification questions, but they didn't
answer

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Customers and saIes channeIs for rectifier transformers
Chemical plants producing Chlorine
End customers:
SaIes channeIs
ABB Rectifiers in:
Switzerland
USA
ndia

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Competitors
Spezial Trasfo
Areva
Siemens
Tamini
Niagara Transformers
Fuji

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VaIue based arguments 1/2
The value based sales arguments are mostly unique to each sales
situation.
t may not be wise to try to make lists of them in this kind of presentations.
To find and recognize a woirking value based sales argument, requires
professionalism, sensitivity, and an opportunity for informal discussions with
the decision makers.
The customer may know such, or not, but it is not his interest to divulgate it
to the seller. The customer may have tactical reasons to try to hide it.
The salesman should personally present the potential value based sales
arguments, one by one, and look and sense the customer's reactions to
each. This is not possible, if the arguments have been sent beforehand to
the customer in written.
Only few carefully pondered arguments should be presented, not all
available at once.

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VaIue based arguments 2/2
Low losses
Different (= better) transformer base concept (two active parts versus one)
Expected longer service free life
Lower life time maintenace costs (f.ex. vacuum swich tap changer)
Better corrosion protection
Oil conservator with membrane, versus "sealed tank system (ANS)
Local ABB service contract for preventive maintenance
Sophisticated oil to water heat exchanger (double tube type)
Mechanical issues, strong bracing of core and windings, foil windings
These examples are technical, but there may be also commercial, logistical, political, or any other
type of arguments, which may be valid, case by case.
Some exampIes of potentiaI vaIue based saIes arguments:

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Transformer cost comparision
ABB's offer
Transformer price 125 000 EUR
No.load losses, 4 kW, 22 800 EUR
Load losses, 45 kW, 208 000 EUR
Cost of losses 230 800 EUR
Total comparative cost:
355 800 EUR
Competitor's offer
Transformer price: 61 500 EUR
No-load losses, 5 kW, 28 500 EUR
Load losses, 65 kW, 300 500 EUR
Cost of losses 329 000 EUR
Total comparative cost:
390 500 EUR
Difference 34 700 EUR
ABB transformer is 8,79 % cheaper!