Steel Industry UPS Case: 1.5MW System Delivers 99% Availability for Zhongtian Steel

Ⅰ. Project Overview

As the core production base of Zhongtian Iron and Steel Group, Zhongtian Iron and Steel Group (Nantong) Co., Ltd. (hereinafter referred to as “Zhongtian Nantong”) is located in Haimen Port New Area, Tongzhou Bay, Nantong City, Jiangsu Province. With a total investment of approximately 100 billion yuan and a planned production capacity of 13 million tons/year, it is the first “5G+Industrial Internet” fully connected steel mill in Jiangsu Province and a national-level green factory.
The company owns advanced facilities such as the world’s first AI+5G pure electric locomotive system and intelligent steelmaking system. In 2024, its revenue exceeded 95 billion yuan, ranking it among the Fortune China 500 list.

With intelligent upgrades, Zhongtian Nantong faces:

High-precision equipment dependency: Continuous 24-hour power supply is required for continuous casting machine frequency converters, intelligent rolling line control systems, etc. Voltage fluctuations >±1% will cause equipment shutdown.
Extreme environmental challenges: The temperature in the blast furnace area reaches over 60°C, and the dust concentration exceeds 10mg/m³. Traditional UPS systems are prone to overheating protection due to insufficient heat dissipation.
Expansion flexibility: Rapid production line iteration requires UPS to support dynamic expansion, which traditional fixed-capacity solutions cannot meet.

Harmonic interference: Rolling mill frequency converters cause THDi (Total Harmonic Distortion of Current) to reach 9%, affecting PLC control accuracy.
Instantaneous overload: The starting current of converter tilting motors reaches 11 times the rated value, making conventional UPS systems prone to overload shutdown.

Decentralized deployment: Independent UPS systems result in a fault response time of over 3 hours.
Battery aging: Lead-acid batteries have a cycle life of only 3,000 times, with an annual replacement cost exceeding 5 million yuan.

Inefficient operation: Traditional UPS systems have an efficiency of 82%, leading to annual electricity costs exceeding 150 million yuan.
Carbon emission reduction pressure: It needs to meet the carbon peak target of the steel industry during Jiangsu Province’s “14th Five-Year Plan” (18% reduction in carbon emissions per ton of steel).

Module	Specifications and Functions
Double-conversion pure online technology	Input power factor >0.99, THDi <3%, output waveform distortion rate <2%
Intelligent parallel control	Supports 8 units in parallel, N+1 redundancy, dynamic load balancing (±0.5% accuracy)

Power quality governance: Deploy DSP full-digital control modules to compensate for harmonics in real time, reducing THDi to below 2%.
Modular expansion: Adopt 6 units of 250kVA UPS in parallel, with a total capacity of 1.5MW and 50% reserved expansion space.
Intelligent O&M: Connect to Zhongtian Iron and Steel’s energy management platform to realize remote monitoring of battery state of health (SOH).

Zero downtime record: System availability reaches 99.999%, with annual unplanned outages <5 minutes.
Fault response: The self-diagnosis system shortens maintenance response time by 80%, with MTTR (Mean Time To Repair) ≤20 minutes.

Harmonic governance: THDi reduced from 9% to 2%, achieving annual electricity cost savings of 28 million yuan.
Battery life: Lithium iron phospha

BK-R11-15KVA-High Frequency Online UPS

References

International Electrotechnical Commission (IEC)Official website: www.iec.ch
Underwriters Laboratories (UL)Official website: www.ul.com
European Committee for Standardization (CEN)Official website: www.cen.eu
Standardization Administration of China (SAC)Official website: www.sac.gov.cn
Zhongguancun Energy Storage Industry Technology Alliance (CNESA)Official website: www.cnESA.org
International Organization for Standardization (ISO)Official website: www.iso.org