Abstract
Power factor correction is a major issue for all industries, since a typical industrial load is causing current delays, as well as higher order current harmonics. Power factor correction is often mandatory from the power companies, usually by charging the reactive power that the company consumes. Many solutions for power factor correction have been presented in the bibliography; in this paper, the most significant power factor correction topologies will be reviewed and simulated with SABER RD software. Finally, a prototype design will be presented, based on a mass/cost analysis of the selected topologies and with an aim to manufacture 10 kW modules. The main outcome of this work is the feasibility for an SME to manufacture a competitive modular power factor correction product for industrial applications.
Highlights
A typical industrial unit contains a large number of nonunity power factor loads
A detailed study of power factor correction topologies for industrial applications has been presented in this paper
It is noted that the power density aim of 3.0 kW/kg has been initiated by the electric vehicle and the aircraft industry and it is a trend that is followed by the majority of the competitive converter manufacturers
Summary
A typical industrial unit contains a large number of nonunity power factor loads. Motor drives and ballast lighting are among the most significant industrial loads that cause current displacement angle, as well as higher order harmonic currents. Power factor correction topologies are mandatory in order to reduce the impact of these loads to the grid. Most of the large industrial units have already installed reactive power compensators in order to reduce the reactive power consumed by the unit, and increase the power factor of the whole unit. The level of integration of such technologies in small and medium enterprises (SMEs) is not satisfactory. This is mainly due to the fact that purchasing such equipment is not expected to have a justifiable economic payback for enterprises of this size. An analysis and evaluation of different threephase power factor correction topologies for industrial use is carried out. The criteria used for the evaluation are mainly cost related; the topologies are examined with regard to their cost (€/kW), efficiency, and power density (kg/kW)
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