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Under the background of the continuous upgrading of power system and the surge of industrial electricity demand, transformer, as the core equipment of electric energy conversion and transmission, its operation stability and life span are directly related to the safe and efficient operation of power network. However, the lack of heat dissipation performance has always been a key bottleneck restricting the carrying capacity and operational reliability of transformers. Shanghai Fengchuang Industrial Co., Ltd. has achieved a major breakthrough in transformer heat dissipation technology with its deep technology in the field of electrical equipment-adopting new cooling materials, greatly improving heat dissipation efficiency, and providing a brand-new solution for the stable operation of transformers under high load and complex environment.
As a national high-tech enterprise integrating R&D, production and sales, Shanghai Fengchuang Industrial Co., Ltd. always takes technological innovation as its core driving force. The transformer products of its "Fengyun-Fonyun" brand have accumulated rich application cases in industrial automation, new energy, rail transit and other fields. Through long-term investigation, the R&D team found that traditional transformers mostly rely on air natural cooling or oil-immersed cooling, which has obvious limitations: air cooling is greatly affected by ambient temperature, and overload protection trips easily due to insufficient heat dissipation in summer; Although oil-immersed cooling has high heat dissipation efficiency, insulating oil has potential safety hazards such as rapid aging, high maintenance cost and flammability, and its fluidity decreases at low temperature, which greatly reduces its heat dissipation performance. Especially in new energy power stations, data centers and other scenes, transformers need to run at full load for a long time, and traditional heat dissipation methods have been difficult to meet the demand.
In view of the pain point of this industry, Fengchuang R&D team has successfully applied two new cooling materials to the transformer cooling system for two years, forming a dual guarantee system of "active cooling+passive cooling". Among them, the application of nano-fluid cooling medium is the core breakthrough: nano-alumina and silicon carbide particles are evenly dispersed in insulating base liquid, and the thermal conductivity of cooling medium is improved by more than 40% through the high thermal conductivity and convection heat transfer enhancement effect of nano-particles. Compared with the traditional insulating oil, the new nanofluid can improve the heat dissipation by 35% at the same flow rate, and has better high temperature resistance. It can maintain stable physical and chemical properties at 150℃ and effectively delay insulation aging.
At the same time, Fengchuang innovatively lays flexible phase change heat dissipation materials on the surface of key heating components of transformer (such as iron core and winding). This kind of material takes paraffin as the base material, and is compounded with graphene thermal conductive layer. When the temperature reaches 60℃, it begins to absorb heat, and each kilogram of material can absorb more than 200kJ of latent heat, which can quickly reduce the temperature of local hot spots. When the temperature drops below 50℃, the material solidifies automatically, and the circulating heat dissipation is realized. This design is especially suitable for the problem of "local overheating" in transformer operation. It can reduce the hot spot temperature of winding by 12-18℃ and significantly reduce the aging rate of insulating materials caused by high temperature.
In order to cooperate with the new cooling materials to exert the best efficiency, Fengchuang has synchronously optimized the heat dissipation structure of the transformer. Micro-channel fin oil tank is adopted. By increasing the heat dissipation area (50% higher than the traditional structure) and optimizing the oil circuit design, the flow efficiency of cooling medium in the oil tank is improved by 25%. At the same time, an intelligent temperature-controlled cooling fan is installed outside the oil tank, and the rotating speed is automatically adjusted according to the real-time temperature of the transformer, thus reducing energy consumption on the premise of ensuring the cooling effect. The whole cooling system realizes the synergy of "material innovation+structural optimization+intelligent control", which increases the continuous operation load of the transformer by 20% and prolongs the service life to more than 1.5 times that of the traditional products.
In practical application, the operating temperature of 10kV dry-type transformer in an industrial park was reduced from 120℃ to 95℃ in high temperature period in summer, which successfully avoided 2-3 trips per week caused by overheating and improved the power supply reliability of the park by 90%. The person in charge of power in the park said: "The transformed transformer can not only stably bear the new load of photovoltaic energy storage equipment, but also save maintenance costs by nearly 80,000 yuan every year without frequent replacement of cooling medium during daily maintenance."
At present, Fengchuang transformer with new cooling materials has passed the certification of National Electric Power Equipment Testing Center, and is suitable for industrial workshops, new energy power stations, high-rise buildings and other scenarios. In the future, Fengchuang will further develop cooling materials with lower energy consumption and higher thermal conductivity efficiency, and plans to launch a hybrid cooling system combining liquid cooling and air cooling, so as to continuously promote the upgrading of transformer cooling technology to high efficiency and intelligence, and provide technical support for the green and low-carbon development of the power industry.
www.fonchuang.com
Shanghai Fonchuang Industrial Co.,Ltd.
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