SIPOREC Heavy Duty Rectifier Reliability that enables you to reach the Top

Transcription

1 SIPOREC Heavy Duty Rectifier Reliability that enables you to reach the Top Likasi - 28 th of November 2017 siemens.com/ mining

2 Content 1. Organization of Siemens 6. SIPOREC Production Locations 2. Overview of SIPOREC - Siemens Heavy Duty Rectifier Components 7. Harmonics and PFC 3. SIPOREC CC Screenshots of Alarm & Messaging System 8. Draft Single Line for new Rectifier Groups 4. Features, Highlights, Ref. of SIPOREC at a Glance 9. Draft Rectifier Groups Customer specific 5. Construction Details and Photos 10. Questions / Answers / Feedback Page 2

3 Content 1. Organization of Siemens 6. SIPOREC Production Locations 2. Overview of SIPOREC - Siemens Heavy Duty Rectifier Components 7. Harmonics and PFC 3. SIPOREC CC Screenshots of Alarm & Messaging System 8. Draft Single Line for new Rectifier Groups 4. Features, Highlights, Ref. of SIPOREC at a Glance 9. Draft Rectifier Groups Customer specific 5. Construction Details and Photos 10. Questions / Answers / Feedback Page 3

4 (HDR) Solutions for Electrowinning and Chemical Plants Production of nonferrous metals in electrolyzes and smelters Copper Zinc Nickel Lead Magnesium Aluminium Steel (ferrous, not in lead) Production in the Chemical Industry Sodium Chlorate Caustic Soda Flour Hydrogen, beside others Page 4

5 Electrolysis Processes in Principle Copper, Zinc and Aluminium (ca. 20%) Copper Ore (ca. 80%) Oxide Ores (lower grades) Sulfide Ores (higher grades) (ca. 96% Cu) Furnaces (1000 o Celsius) Leach solution with impure copper (ca. 70% Cu) (ca. 98% Cu) Anode copper Electrowinning (SX/EW) Acidic electrolyte solution Electrolysis (High DC Current) Copper Cathodes (99,99% Cu) Electrolysis (High DC Current) Zinc blende (ZnS) Roasting/Sintering (900 o Celsius) Zinc oxide (+ Sulphur dioxide -> Sulphur acid) Leach solution Melting/ Casting Zinc Ingots (99,99%) (ca. 70% Zn) Smelter (High DC Current) Bauxite Furnace (1200 o Celsius) Alumina (Al 2 O 3 ) Melting Process (950 o Celsius) Aluminium Ingots (99,99%) Casting (ca. 25% Al) (out of 4 tons) (2 tons) (1 tonne) Page 5

6 HDR at a Glance: From incoming Feeder for Rectifier Transformer to DC Busbar of Electrolyzers and Smelters Main HDR Components: Rectifier transformer(s) Heavy Duty Rectifier (Diodes or Thyristors) Control Cubicle Cooling System Optional (if required): Incoming Feeders to transformers DC Separators DC Busbars Cooling System Control System Monitoring Alarm ka DC per Group kv AC Incoming Feeder Rectifier Transformers Rectifier DC Separators V DC Page 6

7 Our Competences Technological Layout and Calculation Mechanical Layout and Calculation, Statics Hardware Engineering Software Engineering Project Management DC Current Control Factory Acceptance Test Erection Supervision Commissioning Services, Revisions and Spare Parts Site Surveys and Studies (Harmonics, EMC) Cooling System Control System Monitoring Alarm ka DC per Group kv AC Incoming Feeder Rectifier Transformers Rectifier DC Separators V DC Page 7

8 Rectifier Types (Platforms) Rectifier unit type SIPOREC H Available configurations: 6-pulse or 12-pulse Bridge or double-star connection DC current per rectifier unit scalable up to 30 ka (Bridge conn.) rsp. 80 ka (Double star) Rectifier unit type SIPOREC V Available configurations: 6-pulse or 12-pulse Bridge or double-star connection DC current scalable up to 100 ka per rectifier unit SIPOREC = Siemens Power Rectifier, V = vertical, H = horizontal Page 8

9 2 m Heavy Duty Rectifier SIPOREC V Vertical Design, self supporting DC busbar (AC side behind) Here: e.g VDC, 50 ka 48 Thyristors 4 and fuses Dim. approx. Page 9

10 2 m Heavy Duty Rectifier SIPOREC H Horizontal Frame Design AC side DC side Dim. approx. Here: SIPOREC H1 e.g. 300 VDC, 60 ka 72 Thyristors 3,5 and fuses Page 10

11 SIPOREC CC, Rectifier Control System SIPOREC CC is a fully digital Rectifier Control System which supports thyristorcontrolled rectifiers as well as diode-based systems with transductor control. Application for new rectifier groups as well as for modernization Due to its flexible concept, SIPOREC CC can be matched to virtually any rectifier system. The original manufacturer as well as the year of manufacture rather plays a secondary role. Further functional highlights: Comprehensive functions for protection of the rectifier system In-built DC measuring system (Siemens) Integrated diagnosis functions including remote services via VPN Page 11

12 SIPOREC CC, Rectifier Control System Although Heavy Duty Rectifiers are highly specialized, Siemens utilizes industrial standard components whenever this is useful. Clear Advantages: Comprehensive service packages available worldwide Protection of investment through ongoing compatible product development Compatible communication interfaces based on open standards Numerous components already stocked by many customers SIPOREC CC takes advantage from the market-leading PLC family SIMATIC S7 and from the SINAMICS DCM technology. Page 12

13 2,20 m Heavy Duty Rectifier SIPOREC CC, Rectifier Control System 1 1 SINAMICS DCM (DC-Master for Closed-loop control) 3 2 DC Measurement System (Siemens) SIMATIC S7 (Open loop control) Protection Relays (Option) and AC Measurement 5 Operator Panel 6 Contactors, Circuit Breakers, Protection Relays 2,40 m Page 13

14 Standardized Cooling Unit High overload capacities and components of high quality ensure efficient cooling and long maintenance-free intervals Main features of the cooling unit: Compact design, coordinated with the other HDR components Comprising multiple sensors for monitoring of the water circuits Over-pressure free, sealed deionized water system Heat exchangers adaptable to the quality of the raw water Extra capacity provided for compensation of fouling effects Available as highly reliable version with 2 pumps and 2 heat exchangers (as shown) Page 14

15 1,5 m Heavy Duty Rectifier Standardized Cooling Unit Dim. approx. 3 1 Heat Exchanger 2 Pump Local Control 4 Deionized Water System ,0 m Page 15

16 Content 1. Organization of Siemens 6. SIPOREC Production Locations 2. Overview of SIPOREC - Siemens Heavy Duty Rectifier Components 7. Harmonics and PFC 3. SIPOREC CC Screenshots of Alarm & Messaging System 8. Draft Single Line for new Rectifier Groups 4. Features, Highlights, Ref. of SIPOREC at a Glance 9. Draft Rectifier Groups Customer specific 5. Construction Details and Photos 10. Questions / Answers / Feedback Page 16

17 Features at a Glance SIPOREC Rectifiers embody the most advanced electrical and mechanical engineering available, with features that include Highly reliable bus bar arrangement using welded aluminum bus bar connections, extra long creepage paths on all insulation materials and wide air clearances between parts of different voltage potentials Nickel-plating on all aluminum contact surfaces, thus obtaining an even and stable long term ohmic resistance across the entire contact surface Efficient cooling with high overload capacities and long maintenance-free intervals Uniform temperature distribution in the entire rectifier unit by using an adequate number and arrangement of cooling circuits Failsafe design with no earthed parts other than the base frame. Isolation from earth by using 10 kv (or optional 20 kv) post insulators Careful separation of the phases by means of insulating shields made of flame-resistant material with high tracking index, as per IEC recommendations High unit ratings resulting in small space requirements and minimal foundation works (small foot print) Compact design of the rectifier unit, in close proximity to the transformer, for high efficiency and optimal power factor due to short AC busbar connections According the following European Standards: DIN EN (VDE 0532), DIN EN (VDE0532, Teil 41), DIN EN (VDE 0558), DIN EN (VDE 0160), DIN EN (VDE 0110), DIN EN (VDE 0660) Page 17

18 from Siemens Benefits for Customers High reliability of Siemens Systems High efficiency of Siemens Systems One interface to Siemens for the entire HDR system Process Industries and Drives, PD SLN (RU / HQ) Application and Services out of one hand (Siemens internal coordination) Long term maintenance free systems Easy access to the components in case of replacement Page 18

19 Product Description Life Cycle Management The main HDR components have been improved step by step out of feedback through field experiences the last 30 years. Today Siemens offers very high reliable HDR applications. The life cycle of rectifier applications are very long, they are constructed to run in minimum 20 to 30 years. The life cycle of the HDR control system SIPOREC CC is approx years. Industry using HDR applications is relatively conservative, because of necessary high DC power reliability to ensure core production. Page 19

20 Operation & Maintenance After installation and commissioning: Operation 365/24/7 Small maintenance intervall per year for insulation measurements and visual checks (water cooling pipes, etc.) Every 5-7 years a 5-10 days stop for a larger maintenance intervall measurements, exchange of semiconductors (if required), change of water cooling pipes, cleaning of contacts, etc. Service Contracts available Siemens Remote Services (SRS) via Internet/VPN available Main services can be done by regional service departments of Customer Services Large maintenance and escalated (on-call) services will be done with support from HQ Page 20

21 1000 delivered HD Rectifiers for Various High Current DC Applications all over the World Focus Branch Rectifier Plants Rectifier Groups Aluminium Copper Zinc Focus branches Other branches (Hydrogen, Graphitizing, Magnesium, Nickel,...) Total Plants Total rectifier groups installed : approx Page 21

22 Delivery of new Rectifier Systems since of 2 Customer Country Scope Application Date Tessenderlo Chemie Belgium 5 Rectifier Groups, 5x 34 ka IMMSA Mexico 2 Rectifier Groups, 2x 42 ka Zinc Asturiana de Zinc Spain 3 Rectifier Groups, 3x 26 ka Zinc Cumerio Bulgaria 1 Rectifier Group, 42 ka Copper Bayer Germany 3 Rectifier Groups, 3x 54 ka Dead Sea Bromine Israel 1 Rectifier Group, 33 ka OCK Bulgaria 1 Rectifier Group, 200 ka Zinc Asturiana de Zinc Spain 1 Rectifier Group, 130 ka Zinc SGL Carbon Germany 1 Rectifier Group, 60 ka Graphite Asturiana de Zinc Spain 1 Rectifier Group, 130 ka Zinc 2011 Asturiana de Zinc Spain 3 Rectifier Groups, 3x 26 ka Zinc 2011 Montanwerke Brixlegg Austria 1 Reversible Converter System, 50/10 ka Copper 2011 Boliden Finland 1 Rectifier System, 24 ka Copper 2011 Boliden Odda Norway 1 Rectifier System, 110 ka Zinc 2012/2013 CABB Germany 1 Rectifier System, 25 ka 2013/2014 Page 22

23 Delivery of new Rectifier Systems since of 2 Customer Country Scope Application Date Asturiana de Zinc Spain 5 Rectifier Systems, 5x 26 ka Zinc 2014/2015 Spolchemie Czech Rep. 4 Rectifier Systems, 4x 16 ka 2015/2016 Hydro Aluminium Norway 6 Rectifier Systems, 6x 105 ka Aluminium 2015/2017 Emirates Chem. Factory UAE 2 Rectifier Systems, 2x 16,5 ka 2016/2017 IMMSA Mexico Mexico 1 Rectifier System, 1x 42 ka Zinc 2016/2017 Fortischem Slovakia 2 Rectifier Systems, 2x 20 ka 2017/2018 Tessenderlo Chemie Belgium 2 Rectifier Systems, 2x 17 ka 2017/2018 DOW Chemicals Germany 2 Rectifier Systems, 2x 72 ka 2017/2018/19 Page 23

24 Modernization of Rectifier Control Systems since of 2 Customer Country Scope Application Date Solvay Germany 3 Control Systems 2002 Schunk Germany 1 Control System Graphite 2003 Dow Germany 1 Control System 2004 BASF Germany 2 Control Systems 2005 RAPP Indonesia 2 Control Systems 2005 Zinifex Netherlands 4 Control Systems Zinc Boliden Finland 2 Control Systems Copper Solvay Germany 2 Control Systems MW Brixlegg Austria 1 Control System (for reversible converter) Copper Hydro, Neuss Germany 1 Control System Aluminium Hydro, Karmoy Norway 6 Control Systems Aluminium Schunk Germany 1 Control System Graphite Saarschmiede Germany 4 Control Systems (for reversible converter) Steel 2010 ZGH Boleslaw Poland 3 Control Systems Zinc 2010 Borregard Norway 1 Control System 2010 Dow Germany 3 Control Systems 2010 Sabic Netherlands 1 Control System 2011 Norilsk Nickel Finland 1 Control System Nickel 2011/2012 RAPP Indonesia 2 Control Systems Page 24

25 Modernization of Rectifier Control Systems since of 2 Customer Country Scope Application Date Asturiana de Zinc Spain 2 Control Systems Zinc 2012 BAYER Leverkusen Germany 3 Control Systems 2013/2014 SOLVIC S.A. Belgium 2 Control Systems 2014 Aurubis Olen Belgium 1 Control System Copper 2014/2015 RAPP Indonesia 2 Control Systems 2014/2015 SABIC Netherlands 2 Control Systems 2014/2015 CABB Germany 1 Control System 2014/2015 Currenta Dormagen Germany 1 Control System 2017/2018 Page 25

26 Content 1. Organization of Siemens 6. SIPOREC Production Locations 2. Overview of SIPOREC - Siemens Heavy Duty Rectifier Components 7. Harmonics and PFC 3. SIPOREC CC Screenshots of Alarm & Messaging System 8. Draft Single Line for new Rectifier Groups 4. Features, Highlights, Ref. of SIPOREC at a Glance 9. Draft Rectifier Groups Customer specific 5. Construction Details and Photos 10. Questions / Answers / Feedback Page 26

27 Reference Bayer Uerdingen Germany Test Phase SIPOREC V SIPOREC = Siemens Power Rectifiers Page 27

28 Reference Bayer Uerdingen Germany - Installation Page 28

29 Reference Tessenderlo Chemie - Installation DC Alu Busbar, flexible SIPOREC H SIPOREC = Siemens Power Rectifiers Page 29

30 Reference IMMSA Test Phase SIPOREC H AC Busbars SIPOREC = Siemens Power Rectifiers Page 30

31 Construction Details 3D-Drawing SIPOREC H Connection plates made of special aluminum alloy welded directly to the thyristor busbars for optimum contacts SIPOREC = Siemens Power Rectifiers Page 31

32 Construction Details Nickel-plated aluminium surface DC Busbar SIPOREC H Nickel-plating on components as fuses, semiconductors and heat sinks as well as on all aluminum contact surfaces obtaining an even and long term stable ohmic resistance across the entire contact surface. SIPOREC = Siemens Power Rectifiers Page 32

33 Construction Details 3D-Drawing SIPOREC H SIPOREC = Siemens Power Rectifiers Page 33

34 Construction Details SIPOREC H, AC Connections SIPOREC = Siemens Power Rectifiers Page 34

35 Construction Details SIPOREC V AC Connections SIPOREC = Siemens Power Rectifiers Page 35

36 Construction Details Direct water cooling of semiconductors and fuses by means of specially designed cooling bars and boxes Uniform tempered cooling bars through counterflow cooling Easy maintenance through readily accessible vital components, such as diodes / thyristors, fuses, etc. Passive safety by the use of insulating plates between the phases and between individual semiconductors Page 36

37 Construction Details Cu AC connections to trafo Fuse Heat Sink Semiconductor DC Busbar with cooling channel Semiconductor Heat Sink Fuse Cu AC connections to trafo SIPOREC = Siemens Power Rectifiers Page 37

38 Construction Details Press-Pack SIPOREC V SIPOREC = Siemens Power Rectifiers Page 38

39 Option: Rectifier Transformer Combination Test Page 39

40 Rectifier Transformers Page 40

41 Power Factor Correction, Harmonic Filter Page 41

42 Contact Oliver Schein Sales SIPOREC Heavy Duty Rectifier RMK Schuhstraße Erlangen Tel.: +49 (9131) Fax: +49 (9131) Mobil: +49 (172) oliver.schein@siemens.com Page 42