Industry Background:
Chemical fiber production involves four key processes: polymerization, drawing, cooling, and wastewater treatment. The variable-frequency winding machine serves as the core electrical equipment in the drawing stage, while the polymerization process relies on TPA transportation through pipelines after mixing, heating, and reaction. Critical electrical systems in this phase include mixers, variable-frequency centrifuges, and filter towers, complemented by variable-frequency pump drives in heat transfer furnaces and circulating water treatment systems.
A notable operational challenge is the varying harmonic emissions from different inverter types. Particularly in drawing and wastewater treatment, transformer total harmonic distortion (THD) frequently exceeds 25%. Xinxiang—hosting two-thirds of China’s chemical fiber capacity—forms the epicenter of this issue. As a leading power quality specialist, Strong Power has developed extensive expertise in addressing these industry-specific challenges.
Power Quality Assessment:
At a Xinxiang-based chemical fiber plant, Strong Power’s diagnostic revealed:
- Recurrent capacitor bank failures
- Unexplained power factor degradation
- Transformer overheating with excessive audible noise
- Elevated equipment failure rates
- Frequent nuisance circuit breaker trips
Root Cause Analysis:
Data confirmed the presence of 5th, 7th, 11th, and 13th characteristic harmonics from inverters. These harmonic currents induced severe voltage distortion through grid impedance, exceeding international THD limits. The distortion not only compromised equipment safety but also triggered resonant conditions between system impedance and capacitor banks, destabilizing the entire power network.
Engineered Solution:
Strong Power implemented a targeted active power filter (APF) installation on the distribution transformer’s secondary side. Operational data demonstrates the solution’s effectiveness in:
- Containing harmonic pollution
- Maintaining voltage distortion within safe thresholds
- Reducing equipment failures
- Extending critical asset lifespan
Measured Outcomes:
The APF solution delivered transformative results:
- 35% improvement in distribution system stability
- 60% reduction in equipment failure rate
- 8-12% production capacity increase through released system potential
- Significant energy efficiency gains
This case has become the benchmark for power quality management in China’s chemical fiber industry, with Strong Power’s solution now adopted enterprise-wide across Xinxiang’s production cluster.
