Case Studies of Technical and Economic Benefits of Active Harmonic Filter in Induction Furnaces
By providing innovative solutions for Active Harmonic Filter, Honam Part Energy plays a key role in optimizing power quality in industries. This case study examines the effectiveness of Active Harmonic Filter at Qazvin Mofid Glass Factory, focusing on a 250 kW induction furnace that was experiencing high harmonics.
Qazvin Mofid Glass Factory
Qazvin Mofid Glass Factory is one of the active industrial units in Qazvin province that specializes in the production of construction and industrial glass. The factory is located in an industrial area near Qazvin with more than 8 industrial towns. The project location is in an induction furnace production unit that uses a diesel generator and needs an Active Harmonic Filter for energy sustainability.
Induction Furnace
Induction furnaces generate heat with electromagnetic fields and are used to melt materials such as glass. At Qazvin’s Mofid Glass, a 250 kW induction furnace with power converters generates harmonics up to THDi 53%, requiring the use of an active harmonic filter for power quality management.
Measurement equipment
The C.A 8331 from Chauvin Arnoux was used to monitor power quality. With AmpFLEX probes, this analyzer measures parameters such as THD and flicker and helps to adjust the active harmonic filter.
Harmonic Origin and Its Effects
Harmonics arise from nonlinear loads such as induction furnaces and cause distortions of up to 53% THDi. This has led to increased losses and the need for active harmonic filters to solve generator startup problems.
Harmonic measurement table before filter installation
| Location (grid) | THDI (%) | THDU (%) | |
|---|---|---|---|
| Before installing the filter (250 kW induction furnace) | ۵۳ | ۵۳ | ۴.۷ |
Honam Part Energy Active Harmonic Filter
Three 150-amp Honam Part Energy Active Harmonic Filters have been installed with compensation for harmonics of order 2 to 50 and reactive power up to 45 kvar, enabling stable generator startup.
Harmonic measurement table after filter installation
| location (grid) | THDI (%) | THDU (%) |
|---|---|---|
| After installing the filter (250 kW induction furnace) | ۱.۶ | ۱.۵ |
Analysis of results and economic benefits
Installation of Active Harmonic Filter reduced THDi to 1.6% and THDu to 1.5% and brought the power factor to 0.99 has improved. Savings of 120 million rials in energy losses and 200 million rials in costs annually, along with freeing up 25% of generator capacity (500 million rials), have created significant added value.
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