Rectifier Transformer-ER, Leaching, SX and, EW Equipment-Changsha Metalcess Intelligent Equipment Co., Ltd.-Metallurgical Equipment Design and Manufacturing, Process Technology Package Delivery, and Automation Integration

Rectifier Transformer

Metalcess provides a variety of rectifier transformers for high-power DC power supply applications such as electrolytic rectification, DC electric furnaces, etc. They are widely used in pyrometallurgical industries such as copper electrolysis, copper electro-winning, zinc electro-winning, lead electrolysis, tin electrolysis, manganese electrolysis, nickel electrolysis, nickel electro-winning, high-purity iron electrolysis, aluminum electrolysis, etc., as well as in industries such as precious metal recovery, anode slime recovery, and tin smelting where DC electric arc furnaces are used. The performance indicators fully comply with IEC international standards. Our rectifier transformers can reduce the total loss by approximately 10% to 15% compared with the traditional designs. The longest service life of our transformers has currently reached 35 years with an average service life of 30years and can withstand 200% overload for 2 minutes and 150% overload for 10 minutes.

General Introduction of Rectifier Transformer

Product: Special Transformer, rectifier transformer, electric arc furnace transformer, electrolysis transformer, DC arc furnace transformer, AC arc furnace transformer

Applications:

Our rectifier transformers are mainly used in the metallurgical area including the following:

Copper electrolysis, copper electro-winning, zinc electro-winning, lead electrolysis, tin electrolysis, manganese electrolysis, nickel electrolysis, nickel electro-winning, high-purity iron electrolysis, aluminum electrolysis, etc.
precious metal recovery, anode slime recovery, and tin smelting where DC arc furnaces and ore-smelting electric furnace are used.

Standard: ICE

Service: non-standard design, FAT, installation and commissioning guidance, techological process guidance, and after-sales service

Characteristics:

Low loss: reduce the total loss by 10% to 15% compared with the traditional designs.

Strong short-circuit resistance capability: withstand 200% overload for 2 minutes and 150% overload for 10 minutes.

Long service life: The longest service life of our transformers has currently reached 35 years with an average service life of 30 years.

No leakage, low noise, low magnitude of partial discharge

Our company's manufacturing level of special rectifier transformers is at the leading position in the industry. The product structure is advanced and reliable, easy to use, simple to maintain, and has extremely low losses. The performance indicators fully comply with IEC international standards, and various non-standard products can be provided according to user requirements. We can also provide high quality product and service for high-voltage breaking, dual incoming line automatic switching, Silicon controlled rectifier (SCR) rectification, and IGBT rectification.

More information please find and click: Copper Electrolysis Plant, Electric Arc Furnace, Nickel Ore Process, Zinc calcine leaching, and Zinc dust ammonium leaching

Low Loss, Low noise and low temperature rise--Characteristics of Rectifier Transformer

Low Loss, Low noise and low temperature rise

Based on years of research and production practice, through specialized loss-reducing design for rectifier transformers, our company's special transformers can reduce total losses by 10% to 15% compared to traditional designs.

High Quality Material Selection and Liberal Application:

British famous brand extrusion machines is adopted to produce extruded oxygen-free flat copper wires, which have a smooth surface without burrs, high density, and low resistivity. The load loss is lower than that of traditional drawn wires. And by increasing the cross-sectional area of the winding wires, the load loss can be further reduced.

The core is made of high-quality cold-rolled oriented grain silicon steel sheets, which have less leakage flux and low no-load loss. With well selected magnetic flux density and insulating soundproof board placed inside, the magnetic hysteresis vibration noise of the silicon steel sheets is much lower. German Jorg automated shearing is adopted to reduce stray losses. The great verticality and stability of the prepared core also helps reduce noise.

Delicate Structural Design:

By precisely adjusting the "copper-iron ratio" of the transformer, the total losses of the rectifier transformer can be reduced considerably while the short-circuit withstand capability can be guaranteed. In this way, the short-circuit impedance is lowered and the power factor improved.

Select a lower current density to reduce the load loss, lower the temperature rise of the transformer's windings and the top oil, and reduce the noise generated by the current flowing through the conductor.

By computer simulation, calculate the flow resistance, pressure loss in the cooling circuit, and the oil flow velocity at the outlet. Install oil flow guiding baffles in the coils to control the temperature rise of each coil within the specified range.

Internal low-voltage high-current leads are arranged in cophase counter parallel connection to balance the lead reactance and improve the power factor. Unique magnetic isolation measures are taken to reduce stray losses and eddy current losses.

Employ electromagnetic shielding or magnetic interruption to eliminate the local overheating problem of large-capacity transformers. Implement appropriate meaqsures to prevent excessive temperature rise at the ends of the coils.

Strong Short-circuit Withstand Capability--Characteristics of Rectifier Transformer

Strong Short-circuit Withstand Capability of Rectifier Transformer

Our rectifier transformer can withstand 200% overload for 2 minutes and 150% overload for 10 minutes.

The patented technology "multi-layer brush coating stacked leads ring" significantly enhances the short-circuit withdraw capacity of the coil. During the design process, measures such as rigid positioning of the core on six sides are adopted to ensure the stability of the entire product.

Dynamic calculation is used to assess the thermal stability, and a separate voltage regulation coil is set up. At the same time, a series of optimized production process management measures, including coil winding, insulation material sealing preservation, and control of the device body, are adopted to ensure high short-circuit resistance capability.

Our rectifier transformers are widely applied in industries where short-circuit overloads frequently occur, such as three-phase AC electric arc furnaces and DC arc furnaces. Its extremely strong anti-overload capability has also received unanimous praise from customers. After undergoing sudden short-circuit tests at the national testing center and on-site product failure tests, our company's transformers remain undamaged.

No Leakage & Low Magnitude of Partial Discharge--Characteristics of Rectifier Transformer

No Leakage & Low Magnitude of Partial Discharge

Excellent Structure Design

The patented New Type Anti-leakage Trench-type Lead-out Terminal is adopted to completely solve the oil leakage problem of low-voltage high-current terminals.

Based on the principle and performance of partial discharge, the design is optimized. The field strength is adjusted according to the field strength distribution calculation to prevent field distortion.

Strengthen the insulation of the high-voltage outgoing line structure, optimize the lead-out design and the parameters of the discharge and ground distance, as well as the structure of the electrostatic plate, etc.

Production Process Quality Control

A fully enclosed structure purification workshop with constant temperature and humidity is adopted, and the procurement and processing processes are strictly managed in accordance with the ISO9001 procedure to reduce partial discharge caused by improper raw materials and processing and to ensure that no leakage occurs in the transformer during the entire service life.

Harmonic Suppression of Rectifier Transformer

Harmonic Suppression

Both the large current electrolysis industry and the electric furnace smelting industry are facing increasingly strict regulations on grid power quality. By setting the output stagger phase angles of the corresponidng phase on the valve side of multiple main transformers, our transfomers form a equivalent 12-pulse wave, 24-pulse wave, 48-pulse wave and other multi-pulse wave outputs. In this way, the harmonic current injected by the rectifier system into the grid connection point is within the distortion range between what is specified by IEC 61000-2 class 2 and class 3. This fully meets the harmonic requirements of the customer's grid power, and can save a significant amount of compensation capacitor investment. Such technical solution does not generate low-order harmonics in principle and makes our transformers become the optiml solution for harmonic suppression in the industry for now.

FAT (Factory Acceptance Test) for Rectifier Transformer

FAT for Rectifier Transformer

After the rectifier transformer is manufactured, FAT (Factory Acceptance Test) will be conducted before delivery. And clients will be invited to attend the whole process. Below are the list of our FAT test contents.

Shifting operation of the electric gearshift mechanism
DC resistance measurement on winding
Ratio measurement and phase shift angle measurement
Insulation resistance and absorption ratio measurement
No load voltage measurement
External pressure resistance test
Induction pressure resistance test
Performance indicators: loss table, no load loss, load loss, no load current mependance voltage