Development and Design Of a 4000 Amp DC Rectifier for Industrial Metal Scrapping

Guevara N.A.; Tito J.P.; Torres R.R.S. · SSRG International Journal of Electrical and Electronics Engineering (2025) · DOI: 10.14445/23488379/ijeee-v12i7p115

Resumen

This paper presents the development and design of a high efficiency 4000A at 12VDC DC rectifier for metal scrapping, overcoming the limitations of conventional systems such as low energy efficiency of 90-96%, inaccurate current control and frequent maintenance. The proposed system uses PWM modulation with Half-Bridge type IGBTs (15kHz), controlled by an ATmega328P microcontroller and SG3525N integrated circuit, achieving 5 times higher efficiency. An HMI system that allows precise current/voltage adjustments (±2% error), adapting to different metals needed in different ranges, such as copper, aluminum, etc. Advanced protections include alerts, a predictive maintenance system, real-time monitoring, and fast response to failures through an ATMEGA 328P microcontroller and vacuum contactors. Compared to conventional SCR-based rectifiers, the equipment provides 24% higher energy efficiency than SCR, 40% lower downtime and operating costs, and improved purity of recovered metal. This work demonstrates how modern power electronics can optimize industrial metal recycling processes, combining efficiency, automation and robustness for sustainable recovery.

Instituciones: Universidad Nacional de San Agustín de Arequipa