Industrial Furnace Transformers for Smelting & Metallurgy
Furnace transformers represent one of the most mechanically and electrically demanding categories in power engineering. Unlike standard distribution or transmission units, an industrial furnace transformer operates under continuous thermal cycling, repeated operational short circuits, extreme current harmonics, and heavy mechanical forces resulting from magnetic field interactions.
URJA Techniques (India) Pvt. Ltd. manufactures custom-engineered furnace duty transformers up to 10 MVA in the 33 kV class. Designed and rigorously tested in compliance with IS 2026, IEC 60076, and ANSI/IEEE standards, our units power foundries, electric arc smelting operations, ferroalloy extraction, and induction furnace installations across global industrial hubs.
Engineering Built for Extreme Duty Cycles
In electric melting operations, molten metal agitation and electrode positioning generate direct phase-to-phase and dead short-circuits hundreds of times during a single heat cycle. URJA incorporates heavy-duty bracing, high-density insulating materials, and high-tensile electrolytic copper windings to deliver unmatched dynamic short-circuit endurance.
High Secondary Current Capability
Engineered to deliver secondary currents exceeding 100 kA with precisely balanced internal busbar geometry to eliminate localized inductive heating.
Rigid Mechanical Clamping
Heavy-duty structural clamping frames and pre-compressed coil assemblies engineered to absorb repeated electromagnetic surge shocks without winding distortion.
Advanced Harmonic Mitigation
Low-loss Cold Rolled Grain Oriented (CRGO) steel cores engineered to reduce eddy current hot spots caused by intense non-linear furnace harmonics.
Precision Voltage Control
Multi-step On-Load Tap Changers (OLTC) or robust Off-Circuit Tap Changers (OCTC) providing wide tap range flexibility to maintain stable furnace arcs.
Comprehensive Furnace Types Supported
Every metallurgical process requires a tailored magnetic and thermal profile. URJA engineers configure core geometry, impedance values, and winding topologies around specific operational parameters:
- Electric Arc Furnace (EAF) Transformers: Built for direct steel recycling and melting with heavy short-circuit withstand and rapid voltage regulation.
- Submerged Arc Furnace (SAF) Transformers: Designed for continuous reduction of ferroalloys, calcium carbide, and silicon metals under stable high-current conditions.
- Ladle Refining Furnace (LRF) Transformers: Tailored for secondary metallurgical refining, maintaining steady thermal energy control with fine voltage grading.
- Induction Furnace Transformers: Optimized for medium and high-frequency inverter circuits, mitigating inverter harmonics and load fluctuations.
Technical Specifications
| Parameter | URJA Engineering Specification |
|---|---|
| Power Rating | Up to 10 MVA (Custom configurations available) |
| Primary Voltage Class | 11 kV, 22 kV, 33 kV (up to 36 kV system voltage) |
| Secondary Voltage Range | 100 V to 1,200 V (High-current low-voltage execution) |
| Cooling Class | ONAF (Oil Natural Air Forced), OFAF, OFWF (Water Cooled) |
| Winding Material | Electrolytic Prime Grade Copper with High Thermal Index |
| Core Material | High Permeability Grain Oriented (CRGO) Silicon Steel |
| Tap Changing Mechanism | Motorized On-Load Tap Changer (OLTC) / Off-Circuit Tap Switch |
| Applicable Standards | IS 2026, IEC 60076, ANSI C57, IEEE C57.17 |
Industrial Applications
Our furnace duty units serve intensive production environments across worldwide industrial zones, including metal extraction plants in the Middle East, Africa, and Southeast Asia: