GAOHUI Sodium Hypochlorite Generator – 12V 2000A IGBT Rectifier Manufacturer Solution for On-Site Brine Electrolysis

EXECUTIVE SUMMARY
This 12V 2000A industrial electrolysis rectifier is engineered for demanding on-site brine electrolysis applications, serving as the core power source for sodium hypochlorite generator systems. As a leading IGBT rectifier manufacturer, GAOHUI delivers pure, ripple-free DC power to optimize the electro-chlorination reaction, converting 3-phase AC mains into a precise 12 volt 2000 ampere output. Designed for water disinfection chlorine production, this unit eliminates dependency on hazardous bulk chemicals. The switching power supply topology ensures over 90% energy conversion efficiency, directly lowering operational costs compared to traditional thyristor-based systems. For procurement managers seeking a heavy-duty DC power supply price that correlates with decades of lifespan, this system offers a total cost of ownership unmatched by generic alternatives. Every unit undergoes a full-load burn-in test at our industrial high frequency rectifier factory to guarantee field reliability in 24/7 chlorination environments.
PART 1 KEY FEATURES & ENGINEERING HIGHLIGHTS
1. IGBT Full-Bridge Topology
Deploying advanced IGBT modules operating at high switching frequencies, this rectifier achieves exceptionally low output ripple (below 1% at full load). This steady DC voltage directly enhances Faraday efficiency in the sodium hypochlorite generator, reducing salt consumption and heat generation within the electrolytic cell.
2. Energy Saving Management
The power factor corrector maintains PF above 0.93 across all load ranges. Combined with a secondary soft-switching design, the system operates at efficiencies exceeding 92%, significantly reducing kilowatt-hour consumption per kilogram of available chlorine produced.
3. Sealed Liquid-Proof Chassis
Built to IP42 standard, the cabinet protects all 12V 2000A power stages against the corrosive mist and spray typical in on-site brine electrolysis rooms. Stainless steel fasteners and conformal-coated PCBs prevent galvanic attack from chlorine gas.
4. Digital Multi-Language Interface
A 10-inch HMI touchscreen provides real-time visualization of the output rectifier parameters. Operators can adjust current density sliders, set batch timer durations, and monitor cumulative ampere-hours without opening the panel door.
5. Closed-Loop PID Control
An embedded PID controller reads feedback from a built-in current transducer and compensates for load variations instantly. This ensures that even as the brine temperature or concentration fluctuates, the 2000A setpoint remains locked within ±0.5% accuracy.
PART 2 TECHNICAL SPECIFICATIONS TABLE
| PARAMETER | SPECIFICATION |
|——————————-|—————————–|
| AC Input Voltage (3-Phase) | 380V – 480V (±10%) |
| Output Voltage | 12V DC (nominal) |
| Output Current | 2000A DC |
| Rated Output Power | 24 kW |
| Efficiency (at full load) | ≥92% |
| Output Ripple | 0.93 |
| Protection Class | IP42 |
| Cooling Method | Forced Air (Double Fan) |
| Operating Temperature | -10°C to +50°C |
| Enclosure Material | Cold-Rolled Steel (powder coated) |
| Weight | Approximately 185 kg |
| Communication Interface | RS485 Modbus RTU / Ethernet|
| Analog Control Signal | 4-20mA input / output |
PART 3 ADVANCED BUILT-IN PROTECTION SYSTEMS
Operating a IGBT rectifier manufacturer unit in an aggressive chemical environment demands robust self-diagnostics. This GAOHUI power supply incorporates the following redundant protection layers:
– Over-Voltage Protection (OVP): Instant clamp at 14.2V to shield the electrolytic cell from dielectric breakdown.
– Over-Current Protection (OCP): Electronic trip at 2200A within 2 milliseconds; automatically resets after fault clearance.
– Short Circuit Protection: Dedicated fast-acting semiconductor fuses on both DC output bus bars.
– Over-Temperature Protection: NTC thermistors on the IGBT heat sink trigger a forced derating curve at 75°C; hard-stop at 85°C.
– Phase Loss & Under-Voltage Detection: Scans all three input phases continuously; disables PWM drive if any phase drops below 320V.
– Soft-Start Ramp: Output current rises linearly from 0A to 2000A over 5 seconds, preventing mechanical stress on cell connections.
PART 4 TARGET INDUSTRIAL APPLICATIONS
This 12V 2000A rectifier is purpose-built for electrolytic processes where reliability and precise DC control are critical:
A. On-Site Brine Electrolysis for Municipal Water Disinfection Chlorine
Generate 0.8% sodium hypochlorite solution directly at the treatment plant, replacing the logistics and risks associated with delivered bulk sodium hypochlorite or chlorine gas.
B. Industrial Electro-Chlorination System
Used in cooling water treatment for power plants and petrochemical facilities to control biofouling without handling dangerous chemicals.
C. Large-Scale Pool Sanitation
Powers commercial hypochlorite generators installed at water parks and swimming complexes, producing up to 20 kg of equivalent chlorine gas per day at full duty cycle.
D. Wastewater Oxidation
Feeds electrolyzers that produce mixed oxidants for advanced oxidation processes (AOPs) in industrial effluent treatment.
PART 5 CUSTOMIZATION AND TAILORED ENGINEERING SERVICES
GAOHUI offers factory-direct manufacturing flexibility to adapt any custom current voltage rectifier to your specific process. Our engineering team can deliver prototypes in as few as 15 working days:
Adjustable Voltage & Current Range: 1V to 1000V DC and 1A to 100,000A DC. We can precisely match the 12V 2000A unit to your existing electrode array configuration or scale the bus voltage up for higher impedance cells.
Modular Process Control Add-Ons:
– Process Timer: Programmable cycles from seconds to weeks for automated start/stop.
– Multi-Stage Profile Control: Splits the batch into pre-set current ramps for conditioning electrodes.
– Ampere-Minute Integrator: Displays total charge transfer; enables precise chemical dosing calculation.
– Automatic Reverse Polarity (ARP): Scheduled reversal pattern to descale electrodes, extending cell life by up to 300%.
I/O Expansion Capabilities:
– Isolation: Galvanically isolated 4-20mA retransmission of current and voltage.
– Digital Communication: RS485 Modbus RTU, Ethernet/IP, or Profinet for integration with SCADA systems.
– Pulse Function: Adjustable pulsed DC from 1 Hz to 3000 Hz for specialized electro-coagulation or ultrasonic-assisted electrolysis.
Global Voltage Input Compatibilities: Multiple primary taps for 208V, 400V, 480V, 600V, or 690V 3-phase grids, with or without a step-down transformer.
To request a quotation for your industrial high frequency rectifier factory certified power supply, please provide your cell geometry, brine flow rate, and target daily chlorine production capacity. Our sales engineers will confirm the optimal heavy-duty DC power supply price and delivery schedule for your project.