Fosfoquim success story: harmonic filtering and efficiency solution in electrolysis plant

The technical challenge: Need for harmonic filtering due to critical distortion

The phosphate production plant in Talcahuano was using half-wave rectifiers that generated extreme harmonic distortion (THDi > 30%). This lack of harmonic filtering caused:

• Low power factor: Readings below 0.7 with a high risk of regulatory penalties.
• System overload: The 3150 kVA transformer was operating at an actual capacity of only 2205 kVA (134% overload).
• Instability: Presence of flicker and overheating in conductors and switchboards, threatening operational continuity.

The solution: Diagnosis and an advanced harmonic filtering and SVGm system

To stabilise the network, a comprehensive two-stage harmonic filtering strategy was implemented:

1. Measurements and diagnosis: Identification of dominant harmonics (5th, 7th, 11th, and 13th) under the Chilean NTCSD standard.
2. Technological intervention: Installation of a master harmonic filtering system with 22 modules configured to reduce distortion and optimise the power factor.

Impact of harmonic filtering on industrial efficiency

The implementation of harmonic filtering and reactive compensation delivered immediate, measurable results:

• Power quality: THDi dropped from 42.5% to <8%, and THDv stabilised in voltage (<8%).
• Power factor: Improved to >0.95, eliminating penalties and optimising energy use.
• Operational safety: Normalisation of conductor temperature and recovery of transformer capacity to 85% of safe use.
• Compliance: Flicker (Pst and Plt) stabilised within the established legal limits.

Conclusions: Control and reliability through harmonic filtering

The integration of Circutor’s harmonic filtering technologies allowed Fosfoquim to transform a critical system into a model of efficiency.

"This intervention ensures longer equipment service life, mitigation of financial risks, and full real-time visibility of consumption for the Maintenance Manager."