Large Current Rectifiers State of The Art and Future Trends
Large Current Rectifiers State of The Art and Future Trends
Large Current Rectifiers State of The Art and Future Trends
3, JUNE 2005
Abstract—This paper presents the different technologies used losses, which are dissipated with water cooling. The losses are
in the generation of large controlled currents, in the kiloam- so important that they usually are considered in the economic
peres range. After a brief review of processes requiring large evaluation of large current rectifiers.
currents, the paper discusses the working principles of thyristor
phase-controlled rectifiers commonly used in these applications. Reliability is also a critical issue to be considered in the op-
Chopper–rectifiers using high-current insulated gate bipolar eration of these large units due to their important impact on the
transistors are introduced as an alternative being considered in re- production of the plant.
cent projects. The pulsewidth-modulated current-source rectifier, For several years, thyristor rectifiers have been the dominant
currently used in medium-voltage motor drives, is also analyzed technology in large current rectifiers. However, the advent
as a future alternative for rectification in industrial processes.
In addition, this paper presents the most important require- of high-current insulated gate bipolar transistors (IGBTs)
ments and specifications to be considered in the applications of has permitted the introduction of a new alternative called a
these high-power units. A system comparison is developed between chopper–rectifier, which uses a combination of diode rectifiers
thyristor and chopper–rectifiers in terms of quality of control, and power transistors to generate large controlled currents
harmonics, power factor, losses, and efficiency. [4]–[8].
Index Terms—AC–DC power conversion, chopper–rectifiers, This paper summarizes the working principles and main char-
electrochemical processes, phase control, rectifiers, thyristors. acteristics of the most important thyristor and chopper–recti-
fiers. The requirements and specifications necessary to work
I. INTRODUCTION with these units are clearly established. The following sections
also include a system comparison of both technologies consid-
TABLE I
TYPICAL DC RATINGS FOR INDUSTRIAL APPLICATIONS REQUIRING LARGE
CURRENT RECTIFIERS
Fig. 10. PWM current-source rectifiers. (a) Power circuit. (b) Rectifier input current.
thyristor units improves for applications that call for higher TABLE II
rated dc output voltages. Furthermore, the losses in harmonic LOSSES WITH A DC VOLTAGE OF 150 V
filters normally used in thyristor rectifiers makes this compar-
ison even more favorable for chopper–rectifiers.
A detailed comparison of two different thyristor rectifier
topologies and a chopper–rectifier is presented in [8]; all the
units analyzed are 12-pulse and sized to deliver 30 kA dc at
150, 300, and 650 V dc. This analysis includes losses in the
following elements.
For the thyristor rectifier TABLE III
• thyristor conduction; LOSSES WITH A DC VOLTAGE OF 300 V
• transformer;
• ac line filter;
• thyristor snubber;
• ac and dc bus;
• thyristor fuse.
TABLE V
MAJOR COMPONENT LOSSES IN RECTIFIERS TO DELIVER 70 kA, 35 MW
TO AN ARC FURNACE
Fig. 14. Simplified power circuit of a unit used in an arc furnace application.
D. Reliability
Thyristor rectifiers are quite reliable pieces of equipment. It
is common practice to use redundancy on the thyristors to
increase reliability. On the other hand, chopper–rectifiers have
significantly more power semiconductors, making these units
less reliable. However, their topology is also adequate for the
application of redundancy. Furthermore, this redundancy
can be implemented at different levels. First, redundancy
can be applied to the IGBT legs of a simple cell allowing for
disconnection of one of these legs by a fuse in case of failure
[10]. Redundancy could also be introduced by designing a con-
verter capable of operation at rated current with one complete
cell disconnected, should it fail.
TABLE VII [3] R. Brown, “Rectifiers and DC bus system design for the copper
INSTALLED CHOPPER-RECTIFIERS BY SATCON UP TO 2000 electrowining industry,” IEEE Trans. Ind. Appl., vol. 26, no. 6, pp.
1116–1119, Nov./Dec. 1990.
[4] P. Maniscalco, V. Scaini, and B. Urban, “High current DC choppers
and their operational benefits,” in Conf. Rec. IEEE-IAS PCIC, 1998, pp.
173–180.
[5] V. Scaini and W. Veerkamp, “Specifying DC chopper systems for elec-
trochemical applications,” IEEE Trans. Ind. Appl., vol. 37, no. 3, pp.
941–948, May/Jun. 2001.
[6] Robicon Co.. (1999) Harmony Series of AC and DC Power Supplies.
[Online] Available: www.robicon.com
[7] A. Siebert, A. Troedson, and S. Ebner, “AC to DC power conversion now
and in the future,” IEEE Trans. Ind. Appl., vol. 38, no. 4, pp. 934–940,
Jul./Aug. 2002.
[8] A. Stevenson and J. Galloway, “High power rectifiers,” in Conf. Rec.
IEEE-IAS Annu. Meeting, Chicago, IL, Sep. 2001, pp. 1–20.
[9] P. Buddingh and J. St. Mars, “New life for old thyristor power rectifiers
using contemporary digital control,” IEEE Trans. Ind. Appl., vol. 36, no.
5, pp. 1449–1454, Sep./Oct. 2000.
[10] V. Scaini and T. Ma, “High current DC choppers in the metals industry,”
IEEE Trans. Ind. Appl., vol. 8, no. 2, pp. 26–33, Mar./Apr. 2002.
[11] Rockwell Automation. (2002) Power Flex 7000 Medium Voltage Drives.
[Online] Available: www.ab.com
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with new DC/DC choppers,” IEEE Trans. Ind. Appl., vol. 37, no. 4, pp.
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César Silva (M’04) received the Electronic Eng. Rodrigo Álvarez was born in Santiago, Chile, in
degree from the Universidad Técnica Federico 1981. He is currently working toward the M.Sc.
Santa María (UTFSM), Valparaíso, Chile, in 1998, degree in power electronics at the Universidad
and the Ph.D. degree from Nottingham University, Técnica Federico Santa María, Valparaíso, Chile.
Nottingham, U.K., in 2003. His research interests include medium-voltage
Since 2003, he has been a Lecturer in the De- drives and modern control techniques.
partment of Electronic Engineering, UTFSM. His
research interests include low-speed sensorless
control of ac machine drives and the control of
power electronics converters.
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