This 12V 5000A industrial rectifier is engineered for maximum operational uptime in copper electrolysis. It delivers stable DC output for high-volume electrowinning (EW) and electrorefining (ER) operations. Tailored for smelters and scrap recovery facilities, this unit provides precise current density control to maximize cathode purity and minimize energy costs. Whether retrofitting a plant or building a new solvent extraction SX-EW line, this industrial high frequency rectifier factory grade solution ensures reliable, 24/7 performance.
PART 1 KEY FEATURES & ENGINEERING HIGHLIGHTS
ULTRA-HIGH CURRENT STABILITY for copper EW rectifier demands. Dual closed-loop feedback (voltage and current) ensures less than 0.5% ripple at full 5000A output. This is critical for uniform copper deposition and preventing anode passivation.
HIGH EFFICIENCY IGBT INVERTER TOPOLOGY. Our proprietary switching technology achieves over 92% efficiency at full rated load. Significantly lower thermal loss compared to legacy SCR or thyristor designs.
COMPACT MODULAR CHASSIS. A robust IP54-rated cabinet houses the entire system, minimizing floor space in tight plating bay layouts. Front-access modules allow for rapid servicing without interrupting adjacent rectifier cells.
HEAVY-DUTY DC BUS BARS. Silver-plated copper bus bars designed for 5000A continuous current. Low resistance joints prevent hot spots and ensure even current distribution to each cathode and anode bank.
THERMAL MANAGEMENT SYSTEM. Forced air cooling with redundant variable-speed fans. Thermal sensors trigger an alarm at 85°C and automatic shutdown at 90°C, protecting critical IGBT modules from thermal runaway.
PART 2 TECHNICAL SPECIFICATIONS TABLE
| Rated Output Voltage | 12 VDC (nominal, adjustable 10-15 VDC) |
| Rated Output Current | 5000 ADC (continuous, adjustable 200-5100 A) |
| Input Voltage | 3-Phase 380 VAC / 400 VAC / 480 VAC (50/60 Hz) |
| Efficiency at Full Load | > 92% (at 5000A / 12VDC) |
| Output Ripple (peak-to-peak) | < 0.5% (5000A, 12V) |
| Cooling Method | Forced Air (Top Exhaust) |
| Protection Class | IP54 (Indoor Installation) |
| Dimensions (W x D x H) | 1800 x 1200 x 2200 mm (approx.) |
| Weight | ~ 2200 kg (with optional output filter) |
| Operating Ambient Temperature | -10°C to +45°C |
PART 3 ADVANCED BUILT-IN PROTECTION SYSTEMS
Comprehensive safety architecture includes reverse polarity protection for the DC output, preventing catastrophic back-EMF damage from failed loads. Phase-loss detection immediately locks out the system if any input line drops below 180 VAC. The integrated IGBT junction temperature feedback loop adjusts the switching frequency dynamically to prevent device failure. A built-in ground fault monitoring system (GFMS) detects stray currents to ground, triggering a controlled shutdown before electrolyte contamination or fire risk occurs. All system faults are logged in a non-volatile memory buffer.
PART 4 TARGET INDUSTRIAL APPLICATIONS
COPPER ELECTROWINNING rectifier factory. Specifically designed for copper solvent extraction SX-EW tankhouses. Sustains 5000A for high-voltage direct current copper plating from pregnant leach solutions.
COPPER SCRAP ELECTROREFINING. Ideal for anode refining in copper scrap recycling operations. Delivers the precise 12V potential needed to dissolve copper anodes and plate pure cathode copper.
ZINC ELECTRO-WINNING AND METAL SMELTING. Functionally compatible with low-voltage zinc EW processes requiring a 12V band. Validated for nickel, cobalt, and precious metal electrowinning.
OTHER DC POWER INTENSIVE PROCESSES. Suitable for chlorine production, water electrolysis (hydrogen generation), and large-scale hard chrome plating where a stable 12V 5000A continuous DC source is mandatory.
PART 5 CUSTOMIZATION AND TAILORED ENGINEERING SERVICES
This is a base model. We are an experienced IGBT rectifier manufacturer capable of extensive customizations to match exact process specifications. Voltage and current adjustments can be optimized from 1V up to 1000V, and from 1A up to 100,000A. Input is AC from grid; output is DC only. Add-on module options include a Process Timer for automated electrode cleaning, a Multi-Stage Profile Control for ramping current during start-up, and an Ampere-Minute Integrator for true coulomb counting. For automated reversal, we offer Automatic Reverse Polarity (ARP) with adjustable dwell times from 1 to 999 seconds. The soft-start function limits inrush current to less than 200% of rated current over a 5-second ramp. Standard digital interfaces include RS485 Modbus RTU, Ethernet (Modbus TCP or UDP), and 4-20mA analog outputs for PLC integration. For advanced pulse plating, we can integrate a Pulse Function with adjustable frequency from 1 Hz to 3000 Hz and duty cycle from 1% to 99%. To discuss your specific heavy-duty DC power supply price and delivery timeframe, please contact our engineering team.
For immediate quotation or custom current voltage rectifier specifications, call our sales engineering desk. We provide full technical documentation, wiring diagrams, and factory acceptance testing. With over two decades as a IGBT rectifier manufacturer, we guarantee performance as standard.
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