GAOHUI Rare Earth Smelting Rectifier (24V 4000A) for Molten Salt Electrolysis

Executive Summary
This 24V 4000A power supply is a high-frequency IGBT rectifier engineered for the punishing conditions of rare earth smelting via molten salt electrolysis. It delivers extreme DC current stability, controlling current direction and magnitude to ensure efficient, high-purity production of lithium, antimony, and indium. Built by an industrial high frequency rectifier factory, this unit replaces outdated thyristor-SCR technology with 92% peak efficiency and near-zero ripple, solving the thermal runaway and electrode passivation problems common in rare earth applications.
Part 1 Key Features & Engineering Highlights
IGBT Full-Bridge Inverter Topology: Employs a zero-voltage switching (ZVS) design that reduces switching losses by 30% compared to traditional SCR units, delivering a clean, ripple-free DC output essential for molten salt bath stability.
Dual-Loop Constant Current/Constant Voltage Control: A closed-loop feedback system automatically compensates for bath resistance fluctuations caused by temperature drift and feed composition changes, maintaining ±0.5% regulation accuracy.
Industrial Frequency Response: Operating at 20-30 kHz, this power supply eliminates the 50/60 Hz harmonics that cause uneven metal deposition in rare earth electrolysis.
N+1 Redundancy for Critical Processes: Configured with redundant IGBT modules and parallel fan arrays, ensuring production continuity even if a single module fails—a design preferred by every IGBT rectifier manufacturer for mission-critical smelting lines.
Part 2 Technical Specifications Table
| Parameter | Specification |
| — | — |
| Model | GH-RE4000-24 |
| AC Input | 3-Phase 380V ±10% (50/60 Hz) |
| DC Output | 0-24V, 0-4000A |
| Output Regulation | CV ≤ 0.3% / CC ≤ 0.5% |
| Ripple Factor | ≤ 1% at full load (with LCL filter) |
| Efficiency | 92% (rated load, 40°C ambient) |
| Cooling Method | Forced air cooling with redundant fans |
| Protection Class | IP54 (electrolyte splash resistant) |
| Control Interface | 7-inch HMI with touchscreen |
| Communication | RS485 Modbus RTU, Ethernet TCP/IP |
| Dimensions (WxDxH) | 1200 x 800 x 1600 mm |
| Weight | 450 kg |
Part 3 Advanced Built-in Protection Systems
Our high-frequency rectifier includes five layers of active protection tailored to rare earth smelting. An arc detect circuit interrupts output in under 5 ms if a plasma strike occurs across the molten salt electrodes. A tank-level dry-run interlock prevents the power supply from operating when the bath temperature drops below 750°C, avoiding solidification damage. An automatic soft-start ramp prevents inrush current that can burn main contactors. For line brownout protection, the unit holds output steady for 100 ms during a 50% voltage sag, preventing crystal nucleation failure in antimony indium extraction. The heavy-duty DC power supply price includes all these safety systems as standard—no optional upgrades.
Part 4 Target Industrial Applications
Molten Salt Electrolysis for Rare Earth Metals: Designed for harvesting neodymium, praseodymium, dysprosium, and terbium from fluoride-oxide baths at working temperatures exceeding 900°C.
Lithium Manganese Smelting: Optimized for lithium manganese oxide production where gassing control and DC current density uniformity determine cathode purity.
Antimony Indium Extraction: Provides the precise low-voltage, high-amperage output required for antimony and indium electrowinning from chloride solutions.
Electrolytic Refining: Supports secondary precious metal recovery from spent rare earth magnets, operating in pulse mode for enhanced dissolution kinetics.
Part 5 Customization and Tailored Engineering Services
Every custom current voltage rectifier from our factory adjusts to your exact process parameters. We offer DC output ranges from 1V to 1000V and 1A to 100,000A, all single-phase or three-phase AC input converted to pure DC output. Our engineering suite includes a programmable process timer for automated batch starts, multi-stage profile control that ramps current up and down during melt cycles, and an ampere-minute integrator function that sums total coulombs passed for coating thickness or dissolved metal calculations. For complex rare earth purification sequences requiring electrode polarity changes, we integrate automatic reverse polarity with adjustable dwell times. All units include a 4-20 mA analog output for remote data logging, plus RS485 Modbus RTU and Ethernet TCP/IP for full SCADA integration. For tests requiring waveform shaping, pulse functions are available from 1 Hz to 3000 Hz, adjustable in amplitude and duty cycle. We ship directly from our factory, bypassing the typical distributor markup on rectifier pricing, and provide remote commissioning via live HMI screen sharing.