1 EXECUTIVE SUMMARY

This report captures the methodology and calculations performed for sizing the capacitor banks
for Urban Mining power system facility in San Macros, Texas. This is a greenfield project and it
is desired to correct the power factor to limit the reactive power consumption at a minimum.

Capacitor bank were sized and results are presented in a tabular format in order to achieve
desired power factors of 0.85, 0.9 and 0.97.

2 DATA USED IN CALCULATIONS

Data presented in equipment utility motor requirements list and the latest electrical one-line
diagram dated 12/21/18 provided to MTX Systems Engineering was used in the calculations.

Appendix A and B presents the load flows onelines of the scenarios 250T and 1000T
respectively. Load data available for each of the panel boards in the system indicated are
indicated on the one lines.

Appendix C provides a list of data provided to MTX Systems Engineering for evaluation of the
power system. Two columns are added with comments for final completion of the capacitor
bank system evaluation.

MTX-R-000000005 – Capacitors Bank Sizing

3 POWER FACTOR CORRECTION STUDY

3.1 General Procedure

AC electrical equipment typically consumes two types of power: active power (kW) and reactive
power (kVAr):

• The active power P (in kW) is the real power transmitted to loads such as motors, lamps,
heaters, computers, etc. The electrical active power is transformed into mechanical
power, heat or light.

• The reactive power Q (in kVAr) is used only to power the magnetic circuits of machines,
motors, and transformers.

The apparent power S (in kVA) is the vector combination of active and reactive power

The circulation of reactive power in the electrical network has major technical and economic
consequences. For the same active power P, higher reactive power means higher apparent
power, and thus a higher current must be supplied. The circulation of active power over time
results in active energy (in kWh). The circulation of reactive power over time results in reactive
energy (kVArh). Electric utilities bill both these energies and at the same time, electrical
infrastructure may need to be upsized to allow the circulation of reactive power.

For these reasons, there is a great advantage in generating reactive energy at the load level in
order to prevent the unnecessary circulation of current in the network. This is what is known as
“power factor correction”. This is obtained by the connection of capacitors, which produce
reactive energy in opposition to the energy absorbed by loads such as motors. The result is a
reduced apparent power and an improved power factor.

The required power factor correction (Qc) can be calculated using vector subtraction as
illustrated below.
𝑄𝑐 = 𝑃. (𝑡𝑎𝑛𝜑 − 𝑡𝑎𝑛𝜑′ )

Where,
𝜑 = 𝑐𝑜𝑠 −1 (𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟)

𝜑1 = 𝑐𝑜𝑠 −1 (𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟)

MTX-R-000000005 – Capacitors Bank Sizing

3.2 Calculations
Real and Reactive power data was obtained from a load flow calculation using SKM Power
System. Same software tool was used for calculating each power factor correction capacitor
bank.

The tables below capture the current power factor and the results with of the required capacitor
banks, along with the recommended rounded values to the next size up for each bank. Table 4
below captures three scenarios for the desired capacitor banks for a power factor of 0.85, 0.90
and 0.97.

The calculations are performed for scenarios of 1000T and 250T and results are tabulated as
below.

3.2.1 Scenario-1: Plant with loads running for 250T phase.

Table 1 Data from Load flow Calculations

Switchboard kW kVAr Current PF

E-MSBA 764 557 0.808
E-MSBB 1325 1000 0.798
MSBC 853 630 0.804
MSBD 780 575 0.805

Table 2 Calculation Results

Capacitor bank required in kVAr

Switchboard for PF =0.85 for PF =0.90 for PF =0.97
E-MSBA 83.65 187.16 365.81
E-MSBB 179.07 358.48 668.09
MSBC 101.14 216.62 415.89
MSBD 91.20 196.88 379.26

Table 3 Recommended Capacitor Bank Sizes

Recommended sizes in kVAr

Switchboard for PF =0.85 for PF =0.90 for PF =0.97
E-MSBA 100 200 400
E-MSBB 200 400 700
MSBC 150 250 450
MSBD 100 200 400

MTX-R-000000005 – Capacitors Bank Sizing

3.2.2 Scenario-2: Plant with loads running for 1000T phase.

Table 4 Data from Load flow Calculations

Switchboard kW kVAr Current PF

E-MSBA 3180 2330 0.807
E-MSBB 2705 2044 0.798
MSBC 1313 978 0.802
MSBD 780 575 0.805

Table 5 Calculation Results

Capacitor bank required in kVAr

Switchboard for PF =0.85 for PF =0.90 for PF =0.97
E-MSBA 359.45 790.04 1533.11
E-MSBB 367.51 733.83 1365.98
MSBC 164.63 342.40 649.19
MSBD 91.20 196.88 379.26

Table 6 Recommended Capacitor Bank Sizes

Recommended sizes in kVAr

Switchboard for PF =0.85 for PF =0.90 for PF =0.97
E-MSBA 400 800 1600
E-MSBB 400 800 1400
MSBC 200 350 700
MSBD 100 200 400

MTX-R-000000005 – Capacitors Bank Sizing

 APPENDIX-A LOAD FLOW ONE-LINE DIAGRAMS
(SCENARIO-1: 250T CAPACITY)

MTX-R-000000005 – Capacitors Bank Sizing

 APPENDIX-B LOAD FLOW ONE-LINE DIAGRAMS
(SCENARIO-2: 1000T CAPACITY)

MTX-R-000000005 – Capacitors Bank Sizing

APPENDIX-C EQUIPMENT UTILITY MOTOR REQUIREMENTS

MTX-R-000000005 – Capacitors Bank Sizing