Rare Earth Smelting – 24V 4000A High Frequency IGBT Rectifier by GAOHUI

GAOHUI presents a dedicated DC power solution engineered for the demanding electrolytic reduction processes in rare earth smelting. This 24V 4000A industrial high frequency rectifier factory direct unit delivers unparalleled current stability and precise output control, addressing the core operational needs of modern rare earth metallurgy. Designed to replace inefficient legacy thyristor systems, this industrial high frequency rectifier factory grade equipment significantly reduces energy loss and improves metal purity.
PART 1 KEY FEATURES & ENGINEERING HIGHLIGHTS
High-Efficiency IGBT Inverter Topology. Utilizes modular IGBT power stages operating at 20-50kHz switching frequency, achieving a system efficiency exceeding 90% at full load. This reduces the heavy-duty DC power supply price of ownership through substantial electricity savings during continuous electrolysis.
Ultra-Stable DC Output. Closed-loop control ensures ripple current below 1.5% RMS. This is critical for uniform crystal growth in rare earth molten salt baths, preventing dendrite formation and ensuring consistent alloy composition. As an IGBT rectifier manufacturer, GAOHUI emphasizes precision in current regulation for smelting.
High Power Density & Compact Footprint. The high-frequency design reduces transformer and filter capacitor size by 60% compared to traditional 50Hz SCR units, saving valuable factory floor space and simplifying installation in process lines.
Robust 24/7 Industrial Construction. Built with heavy-duty busbars, industrial-grade electrolytic capacitors, and forced air cooling with IP54 rated enclosures. The system is designed for ambient temperatures up to 45°C.
PART 2 TECHNICAL SPECIFICATIONS TABLE

PART 3 ADVANCED BUILT-IN PROTECTION SYSTEMS
Comprehensive safeguards for both the equipment and the electrolytic cell. Logic includes instantaneous overcurrent (IoC) clamping at 110% rated current, phase loss detection, overtemperature shutdown via PT100 sensors on heat sinks, and surge suppression per IEC 61643-11. A ground fault detection system continuously monitors insulation integrity. A soft-start circuit limits inrush current to 120% of rated value, protecting upstream transformers and breakers.
PART 4 TARGET INDUSTRIAL APPLICATIONS
This custom current voltage rectifier is specifically tuned for the steady DC demands of rare earth metal production, directly powering electrolytic cells for neodymium, dysprosium, praseodymium, and samarium-cobalt alloys. It is also well-suited for other molten salt electrolysis processes producing lithium, magnesium, sodium, and calcium. Can serve as a primary power supply for graphite furnace melting, sintering, and solvent extraction.
PART 5 CUSTOMIZATION AND TAILORED ENGINEERING SERVICES
GAOHUI delivers complete customization for production line integration. Our factory supports adjustable ranges from 1V to 1000V and 1A to 100,000A, with standard input AC (3-phase) and output DC only. We can integrate modules including a Process Timer for dosing control, Multi-Stage Profile Control with up to 32 programmable steps, an Ampere-Minute Integrator for total charge measurement, Automatic Reverse Polarity for periodic current reversal, and a dedicated Soft-Start profile. Control upgrade options include full RS-485 Modbus RTU, Ethernet IP, 4-20mA analog interface, and Pulse Function adjustable from 1 to 3000 Hz for specialized pulse plating or duty cycle optimization.