Rare Earth Smelting Power Source 24V 4000A Industrial Electrolysis Rectifier IGBT

This 24V 4000A industrial power supply is engineered for the harsh chemical and thermal environment of rare earth smelting via molten salt electrolysis. Designed for continuous duty, it provides the precise current control and high efficiency required for extracting and refining metals like lanthanum and neodymium. Operating from standard three-phase AC input, the unit delivers stable DC output with a system efficiency exceeding 90%, drastically reducing operational costs compared to legacy thyristor-based systems. This unit is a direct upgrade for any industrial high frequency rectifier factory looking to replace older equipment or scale up production capacity in their electrolysis circuit.
Part 1 Key Features & Engineering Highlights
HIGH FREQUENCY IGBT SWITCHING: Core power stage utilizes modular IGBTs switching at 20-50kHz, delivering a smooth, low-ripple DC waveform critical for uniform metal deposition in the smelting cell. This technology minimizes electrical losses and thermal stress on the transformer.
HIGH EFFICIENCY & POWER FACTOR: Achieves greater than 90% total system efficiency across a wide load range. An integrated power factor correction (PFC) circuit maintains near-unity power factor, reducing reactive power penalties charged by the utility.
MODULAR, HOT-SWAPPABLE ARCHITECTURE: The rectifier is built with parallel IGBT modules. If a single module fails, the system continues operating at reduced capacity, and the module can be replaced without shutting down the entire production line. This is essential for continuous smelting operations.
ADVANCED DIGITAL CONTROL: A 32-bit DSP (Digital Signal Processor) governs output with 0.5% voltage and current regulation accuracy. The control system offers both constant current (CC) and constant voltage (CV) modes, with automatic crossover.
Part 2 Technical Specifications Table
Parameter | Specification
— | —
Input Voltage | 3-Phase, AC 380V ± 10% (or customized)
Input Frequency | 50 / 60 Hz (auto-sensing)
Output Voltage | DC 0 – 24V (continuously adjustable)
Output Current | DC 0 – 4000A (continuously adjustable)
Regulation Mode | Constant Current (CC) / Constant Voltage (CV)
Cooling Method | Forced Air (industrial grade fans with filter)
Operating Temperature | -10°C to +50°C
Protection Class | IP20 (with options for IP54 or higher)
Efficiency | > 90% at full load
Part 3 Advanced Built-in Protection Systems
The unit is hardened against the high-inductance load of an electrolytic smelter. Standard protection includes: Overvoltage Protection (OVP), Overcurrent Protection (OCP), Over Temperature Protection (OTP) with automatic fan speed control, Short Circuit Protection (SCP), Phase Loss Protection, and DC Bus Under/Over Voltage Trip. All alarm conditions are logged to an internal memory buffer for diagnostics.
Part 4 Target Industrial Applications
PRIMARY APPLICATION: Rare Earth Smelting (molten salt electrolysis) for metals separation, including lithium, neodymium, dysprosium, and cerium reduction.
SECONDARY APPLICATIONS: Chlor-alkali production, copper foil electrodeposition, metal refining, and electroplating for high-value corrosion-resistant coatings. For procurement teams evaluating a heavy-duty DC power supply price, this unit offers the lowest total cost of ownership over a 10-year life cycle due to its high efficiency.
Part 5 Customization and Tailored Engineering Services
As a professional IGBT rectifier manufacturer, we modify every aspect of the power supply to match your exact smelting process. Our factory offers complete custom current voltage rectifier solutions. Voltage range: 1V – 1000V. Current range: 1A – 100,000A. Input is AC mains; output is DC only.
We integrate optional control modules on demand:
Process Timer: Set precise duration for batch operations.
Multi-Stage Profile Control: Program a ramping current profile to avoid thermal shock to the cell during startup.
Ampere-Minute Integrator: Calculates total charge passed for precise material deposition accounting.
Automatic Reverse Polarity: For periodic polarity reversal to clean electrodes or refine specific elements.
Soft-Start: Prevents inrush current when powering inductive loads.
Interfaces: RS485 Modbus RTU, Ethernet for SCADA/DCS integration, and 4-20mA analog output for remote monitoring.
Pulse Functions: 1 to 3000 Hz adjustable pulse frequency with variable duty cycle (1-99%) for specialized electro-winning applications.
Get in touch with our engineering team to discuss your specific rare earth smelting parameters.