Amorphous alloy transformers, developed in the 1970s, are a new type of power transformer that uses amorphous alloys as the core material instead of silicon steel sheets. Compared to transformers with silicon steel cores, they reduce no-load losses by approximately 70%-80% and no-load current by about 85%. These transformers are currently among the most energy-efficient distribution transformers available, making them ideal for use in areas with low distribution utilization and high fire safety requirements, such as rural power grids, high-rise buildings, commercial centers, subways, airports, stations, industrial and mining enterprises, and power plants.
Amorphous Alloy Ribbons
Amorphous alloy ribbons are produced by combining elements like iron, cobalt, carbon, silicon, and boron in specific proportions. These elements are melted at high temperatures and then rapidly cooled using a high-speed rotating wheel at a cooling rate of 10°C/s. This rapid cooling prevents the metal from forming distinct crystal lattice interfaces, resulting in a random, amorphous structure.
Formation of Amorphous Alloys
Typically, when metals or alloys solidify from a liquid state, the atoms transition from a disordered arrangement in the liquid phase to an orderly arrangement in the solid phase, forming a crystalline structure.
However, if the cooling rate is extremely high, the atoms do not have time to arrange themselves orderly and instead are "frozen" in place, resulting in a disordered atomic arrangement similar to that found in liquids—this is known as an amorphous alloy.
For pure metals to form an amorphous structure, an extremely high cooling rate is required. Due to current technological limitations, achieving such high cooling rates in practical production is challenging, making it difficult to produce amorphous structures from pure metals.
To obtain amorphous metals, metals are typically mixed with other substances. An alloy is formed when materials with different atomic sizes and properties are combined. These alloys have much lower melting points than pure metals and are more likely to form an amorphous structure during cooling.
The amorphous alloy used in transformer cores is an iron-based amorphous alloy, solidified into ribbons at a cooling rate of one million degrees per second, with a thickness of only 0.03 mm.
Advantages of Amorphous Alloy Transformers
Energy Efficiency
Due to the use of amorphous alloy cores and an innovative three-phase three-column manufacturing process, the core loss is significantly reduced, and no-load loss is approximately 25% of that in conventional dry-type transformers.
Although the initial investment in amorphous alloy cores is higher, the extremely high efficiency and energy-saving characteristics of amorphous alloy transformers allow for the recovery of additional investment within 3-5 years at an average load of 60%. Over the 30-year lifespan of the transformer, considerable savings in electricity costs can be achieved.
Reliability
H-Class Insulation (operating temperature 180°C): High heat resistance;
Durable: Can withstand harsh storage and transportation conditions;
Robust Performance: Capable of normal operation under adverse conditions (including climate and geographical environments); can operate at 120% load for extended periods;
Short-Circuit Resistance: Excellent short-circuit resistance;
Maintenance-Free: The transformer is virtually maintenance-free under normal usage.
Safety
Non-Flammable: The transformer will not ignite, can resist fire, and will not explode or emit harmful gases during operation;
Insensitive to Temperature, Dust, and Pollution: Less affected by environmental factors;
No Cracking: The transformer will not develop cracks over time;
Environmental and Human Safety: Safe for the environment and human health during use, with no harmful impacts on other equipment.
Environmental Benefits
Eco-Friendly: The product does not cause environmental pollution during manufacturing, transportation, storage, or operation;
Recyclable: The coil can be recycled at the end of its service life, allowing for resource reuse without environmental harm;
Low Noise: Innovative core structure and advanced manufacturing processes ensure that the noise level of amorphous transformers is 4-5 dB below the current national standard.
A 2000 kVA SCRBH15-2000 amorphous dry-type transformer operating at a 60% load can save approximately 24,000 kWh of electricity annually. At a rate of 1 RMB per kWh, this equates to an annual savings of 24,000 RMB. Currently, the market price for an SCB10-2000 product is around 450,000 RMB, while an amorphous dry-type transformer is about 550,000 RMB, approximately 20% more expensive. However, the reduction in operating costs over five years can offset the higher initial purchase cost.