High-Temperature Insulating Material Solution for Electric Furnace Transformers

Background & Challenge​
Electric furnaces operate for extended periods under harsh conditions involving high temperatures, dust, etc. Traditional transformer insulation materials experience accelerated aging in these environments, leading to insulation failure, reduced lifespan, and even unplanned furnace shutdowns, significantly impacting production efficiency.

​Core Strategy​
Implement a dual-pronged approach to ensure transformer reliability and long-term operation under extreme high temperatures:

1. ​High-Performance High-Temperature Insulation System​
2. ​Enhanced Cooling Structure Design​

​Key Implementation Measures​

​1. Application of Special Insulating Materials​

• ​Conductor Insulation Upgrade:​​ Utilize Class H (180°C) or higher temperature-resistant enamelled wires (e.g., polyimide, nano-composite coatings) to ensure winding insulation strength does not degrade under prolonged high temperatures.
• ​Solid Insulation Reinforcement:​​ Employ inorganic insulating paper (mica paper, NOMEX®, etc.) for interlayer/inter-turn insulation, replacing traditional organic materials. Tolerant to temperatures ≥220°C, eliminating carbonization risks.
• ​High-Temperature Treatment of Structural Components:​​ Upgrade auxiliary components (e.g., insulating bobbins, barriers) to high-temperature engineering plastics or laminated composite materials, achieving consistent high-temperature resistance throughout the entire insulation system.

​2. Optimized Efficient Cooling System​

• ​Heat Dissipation Area Doubling Design:​​ Significantly increase the surface area of enclosure cooling fins (over 30% more than conventional designs) and adopt corrugated tank structures to maximize natural convection cooling efficiency.
• ​Intelligent Airflow Duct Configuration:​​ Optimize internal airflow duct layout based on thermal simulation data to eliminate cooling dead zones. Pre-set forced air cooling duct interfaces for rapid integration with site fans when needed.
• ​Heat Dissipation Surface Treatment:​​ Apply high-emissivity thermal radiation coatings (emissivity ≥0.9) to cooling fin surfaces, enhancing thermal radiation efficiency by over 20%.

​Expected Results​

• Enhanced Stability:​ Insulation system temperature class upgraded from Class B (130°C) to Class H (180°C) or higher, capable of withstanding ambient temperatures ≥70°C.
• Extended Lifespan:​Transformer design life increased to 15-20 years (compared to 8-12 years for conventional electric furnace transformers), reducing equipment replacement costs.
• Optimized Energy Efficiency:​ Thermal losses reduced by 8-12%, achieving overall operational efficiency improvement of ≥1.5%.

​Solution Value Summary​
This solution delivers a breakthrough through dual-path innovation – materials and structure – decisively resolving the critical pain point of transformer insulation aging caused by high-temperature environments. It provides round-the-clock reliable power supply assurance for electric furnace equipment in metallurgy, chemical processing, foundry, and related industries, significantly reducing the losses associated with unplanned downtime.