Ningxia Iron & Steel Group UPS Project: Industrial-Grade Case for Steel Smart Manufacturing

Ⅰ. Project Overview

1. Enterprise Background
   • Ningxia Iron & Steel Group (Ninggang Group) is the largest modern steel complex in Ningxia Hui Autonomous Region, with an annual capacity of 2 million tons. It owns key equipment including 230m²/260m² belt sintering machines, 1350m³/1580m³ blast furnaces, 60-ton converters, continuous casters, and rolling lines, serving construction and machinery manufacturing sectors.
   • As a national high-tech enterprise certified by ISO 9001 and ISO 14001, it focuses on green intelligent manufacturing.
2. Power Protection Requirements
   • Critical Equipment: PLC control systems, continuous caster inverters, and data center servers require 24/7 power supply.
   • Environmental Challenges: High-temperature (45℃+) and dusty conditions in blast furnace areas prone to overheating failures in traditional UPS.
   • Instantaneous Overload Risk: Converter tilting motor startup current reaches 7-11 times the rated value, causing conventional UPS shutdowns.

Ⅱ. Core Challenges

1. Power Quality and Reliability
   • Harmonic interference from rolling mill inverters leads to THDi (Total Harmonic Distortion) of 8%, shortening equipment lifespan.
   • Voltage sags caused by blast furnace blower startups threaten PLC control accuracy.
2. O&M Management Pain Points
   • Decentralized UPS deployment at 32 power supply points across the plant results in response times exceeding 2 hours.
   • Lead-acid batteries (3,000 cycles) incur annual replacement costs of over 3 million RMB.
3. Energy Efficiency Bottlenecks
   • Traditional UPS operates at 82% efficiency, with annual electricity costs exceeding 8 million RMB.
   • Need to meet Ningxia’s “14th Five-Year Plan” target of 15% energy consumption reduction per unit output value for carbon peaking.

Ⅲ. Solutions

1. Technical Architecture

2. Implementation Strategy
   • Deploy DSP full-digital control modules to compensate harmonics in real time, reducing THDi to below 2%.
   • Adopt 4×100kVA UPS in parallel (400kVA total), reserving 30% expansion space.
   • Integrate with Ninggang Group’s energy management platform for remote battery state of health (SOH) monitoring.

Ⅳ. Project Achievements

1. Enhanced Power Reliability
   • System availability reaches 99.999%, with annual unplanned downtime < 5 minutes.
   • Self-diagnosis system shortens maintenance response time by 70%, with MTTR (Mean Time to Repair) ≤ 30 minutes.
2. Energy Efficiency Optimization
   • THDi reduction from 8% to 2% saves 12 million RMB annually in electricity costs.
   • Lithium iron phosphate batteries (10,000 cycles) reduce annual maintenance costs by 75%.