Lead electrolysis rectifier units are key equipment in the lead smelting and refining process. The compatibility of the rectifier equipment significantly impacts the quality of electrolytic lead and the cost of electricity. A complete rectifier system includes a rectifier cabinet, digital control cabinet, rectifier transformer, pure water cooler, and DC sensors. It is typically installed indoors near the electrolytic cell, using pure water cooling, and has input voltages of 35KV, 10KV, etc.
I. Applications
This series of rectifier cabinets is mainly used for different types of rectifier equipment and automated control systems in the electrolysis of non-ferrous metals such as aluminum, magnesium, manganese, zinc, copper, and lead, as well as chloride salts. It can also serve as a power supply for similar loads.
II. Main Cabinet Features
1. Electrical Connection Type: Generally selected based on DC voltage, current, and grid harmonic tolerances, with two main categories: double-anti-star and three-phase bridge, as well as four different combinations of six-pulse and twelve-pulse connections available.
2. High-power thyristors are used to reduce the number of parallel components, simplifying the cabinet structure, reducing losses, and facilitating maintenance.
3. Components and fast-melting copper busbars are made of specially designed circulating water circuit profiles for efficient heat dissipation and extended component lifespan.
4. Component press-fitting employs a typical design for balanced and fixed force distribution, with double insulation.
5. Internal water pipes use imported reinforced transparent soft plastic tubing, resistant to both hot and cold temperatures, and with a long service life.
6. Component radiator faucets undergo special treatment for corrosion resistance.
7. The cabinet is machined using fully CNC machine tools and features overall powder coating for an aesthetically pleasing appearance.
8. Cabinets are generally available in indoor open, semi-open, and outdoor fully sealed types; cable entry and exit methods are designed according to user requirements.
9. This series of rectifier cabinets utilizes a digital industrial control trigger control system to ensure the equipment...
III. Technical Characteristics
1. Regulator: Digital regulators offer flexible and variable control modes and stable characteristics, while analog regulators provide rapid response. Both employ DC current negative feedback control, achieving a current stabilization accuracy better than ±0.5%. 2. Digital Trigger: Outputs 6-phase or 12-phase trigger pulses, with a double narrow pulse pattern spaced 60° apart, strong trigger waveform, phase asymmetry ≤ ±0.3°, phase shift range 0~150°, and single-phase AC synchronization. High pulse symmetry.
3. Operation: Touch key operation for power-on, power-off, and current adjustment.
4. Protection: Includes no-current start, two-stage DC overcurrent alarm protection, feedback signal loss protection, water pressure and temperature over-limit protection, process interlock protection, and operating control angle over-limit indication. It can also automatically adjust the transformer tap position based on the control angle.
5. Display: LCD display shows DC current, DC voltage, water pressure, water temperature, oil temperature, and control angle.
6. Dual-channel product: During operation, the two channels serve as hot standby for each other, allowing for maintenance without shutdown and switching without (current) disturbance.
7. Network Communication: Supports multiple communication protocols including Modbus, Profibus, and Eathernet.
Voltage Specifications:
16V 36V 75V 100V 125V 160V 200V 315V 400V 500V 630V 800V 1000V 1200V 1400V
Current Specifications:
300A 750A 1000A 2000A 3150A 5000A 6300A 8000A 10000A 16000A 20000A 25000A 31500A 40000A 50000A
63000A 80000A 100000A 120000A 160000A
Introduction to Lead Electrolysis Power Supplies
Lead electrolysis power supplies are generally low-voltage, high-current, constant-current adjustable DC power supplies.
Taking the matching rectifier cabinet: KGHS-10KA/70V as an example:
I. Main System Configuration: Double-star, same-phase, reverse-parallel thyristor rectification method. Each rectifier unit consists of one on-load tap-changing transformer and one 10KA thyristor rectifier cabinet, forming a 6-phase rectification.
II. Voltage Regulation Method: On-load autotransformer coarse regulation; fine regulation using thyristor phase-controlled voltage regulation.
III. Equipment Supply Status (Single Unit)
Item No. Equipment Name Model/Specification Quantity Remarks
1 Thyristor Rectifier KHS-10KA/70V 1 unit
2 Control Cabinet KS-20 1 unit
3 DC Sensor C14-12KA 1 unit
4 Water-cooled Air Cooler LSS-60B 1 unit
5 Computer Backend CT-1 1 set
IV. Rectifier Parameters:
Rectifier Transformer Model: ZHPPS-1000/10
Voltage Regulation Range: 65%-105%
Pulse Count: 6 pulses per unit
Number of Voltage Regulation Stages: 9-stage on-load tap changer regulation.
V. Rectifier Cabinet Control and Protection:
5.1 Water circuit connections for rectifier element water coolers, rectifier bridge arms, and fast-acting fuse bridge arms shall employ scientific connection methods to minimize electro-corrosion. Stainless steel pipes shall be used, and all water nozzles shall be secured with stainless steel bolts to ensure leak-free operation under hot conditions. Flange connections shall be used where installation and disassembly are convenient.
5.2 Pure water cooling for the main rectifier cabinet: The main cooling water manifold shall be made of stainless steel, with one inlet and one outlet pipe per cabinet. All water circuits shall be connected using rubber-reinforced pipes with mesh reinforcement. The water circuits must withstand a 30-minute test at 0.4 MPa water pressure without leakage, and the pipes must be easily and quickly disassembled.
5.3 Ensure rectifier elements have sufficient contact pressure, rectifier arms have sufficient mechanical strength, economical current density, and good cooling effect.
5.4 Main circuit overvoltage protection. The system shall effectively absorb operational overvoltages and atmospheric overvoltages, and effectively absorb lightning strike overvoltages to ensure safe production operation.
5.5 Thyristor element commutation overvoltage protection. 5.5 Thyristor Component Fault Protection. A fast-acting fuse connected in series with the thyristor component is installed closest to the thyristor element, with the wiring as short as possible, to provide thyristor commutation protection.
5.6 Thyristor Component Fault Protection. A fast-acting fuse is used for protection. When one fast-acting fuse blows, a fault indication is sent to the corresponding arm component; when two fast-acting fuses blow, the pulse is blocked.
5.8 Overcurrent Protection and Overload Alarm. When a short circuit occurs in the load or the current exceeds 105% of the rated value, an overcurrent protection signal is sent to the PLC and an alarm is triggered. When the load current exceeds 110% of the rated value, the system issues an overload alarm signal and shuts down. (Settings can be adjusted on the host computer control system).
5.9 Overheat Protection. Thermocouples monitor the circulating water temperature, and the collected analog signal is sent to the PLC. When the cooling water outlet temperature exceeds the set value, the PLC issues an overheat alarm signal. (Settings can be adjusted on the host computer control system).
5.10 Underpressure Protection. A pressure transmitter is installed on the stainless steel main water inlet pipeline. The collected analog signal is sent to the PLC. When the inlet water pressure is below 0.1MPa or the water supply is interrupted, the PLC issues a low water pressure alarm signal. (The setpoint can be adjusted on the host computer control system).
5.11 Fuse Failure Alarm Monitoring System: The current operating status of all fast-acting fuses is reported to the PLC via communication through the fuse detection device. The overall alarm signal is also reported to the PLC via a pair of passive contacts. The operating status of all fast-acting fuses in the equipment is displayed on the touch screen and the host computer. In case of a fault, the location of the damaged fuse can be quickly located. A green display indicates normal operation, while a red alarm indicates a fault, facilitating troubleshooting.
5.12 Feedback Off-Circuit Fault Protection: When the current feedback signal is open, the current stabilization control system automatically switches to open-loop operation and sends a feedback off-circuit fault signal to the PLC.
VI. Computer Backend The computer backend can monitor and adjust the rectifier voltage and current of the rectifier cabinet in real time. It can also monitor the operating status of each fast fuse, the operating temperature of each thyristor, the circulating water pressure and temperature, and the transformer oil temperature in real time. Protection parameters can be set and calibrated, and interfaces are available for electrolysis process parameters (voltage per cell, online pH monitoring, etc.) and electrolysis process linkage protection.
