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Application of Frequency Control Technology in Sintering Process
With the rapid advancement of electronic technology, AC speed control has evolved significantly, and frequency conversion speed control has emerged as a key direction in modern power transmission systems. This technology plays a crucial role in energy conservation, reducing maintenance costs, improving product quality and production efficiency, and enabling automation. As a result, it is widely adopted in modern industrial applications. From traditional DC and slip motor drives to the implementation of frequency conversion techniques, motor speed control methods have undergone major transformations. Therefore, understanding the characteristics and benefits of inverter-driven systems is essential.
Looking at various domestic and international inverter brands, their features are quite similar: they can control standard motor speeds and are also applicable to other types of motors. Motors can operate at high speeds while being compact, and they offer explosion-proof capabilities. Inverters allow continuous speed adjustment, reduce starting current, and maintain stable speed regardless of load changes. They also provide adjustable acceleration and deceleration times, and with vector control, they deliver fast response and precise control, often replacing DC motors. The main advantages of using inverters include energy savings, improved equipment reliability, enhanced control accuracy, and better overall performance.
In industrial and mining enterprises, inverters help solve complex operational challenges and bring substantial economic benefits. One of the most common applications is speed control using various types of frequency converters. In our factory, they are primarily used for controlling fan speeds and constant-torque systems. Fan and pump systems have a unique characteristic: the load torque is proportional to the square of the speed, while the shaft power is proportional to the cube of the speed. Previously, motors operated at constant speed, and air volume was adjusted using damper valves, resulting in significant energy waste. By adjusting the motor speed according to the required air volume, we achieve substantial energy savings.
Different speed control methods have varying levels of efficiency. Inverter control comes closest to the ideal performance curve and offers more noticeable energy-saving benefits. For constant-torque loads such as sintering disk feeders and electronic scale belts, variable frequency speed control can also lead to energy efficiency improvements. When the motor speed decreases, its output power drops accordingly, which in turn reduces the input power of the inverter, leading to lower energy consumption.
Raw material blending is a critical step in the sintering process. It involves mixing iron ore, fluxes, fuel, and other materials in specific proportions to ensure the chemical composition meets set standards and remains stable. The stability of this process directly impacts the quality of the sintered ore. Before the adoption of frequency converter control, raw material blending relied on slip motor systems, which were inefficient, energy-intensive, difficult to maintain, and led to poor working conditions and frequent equipment failures. To address these issues, we integrated frequency conversion technology with computer systems and used pressure sensors for real-time monitoring, creating an advanced electronic weighing system for raw material blending. After implementing this system, the batching control became much more accurate, easier to operate, and significantly improved the overall production efficiency.