Abstract

This paper proposes an optimized sequential control technique for copper electrowinning high-current rectifiers, The converter comprises two series-connected six-pulse double-wye rectifiers, a step-down transformer, and a tuned input filter. The six-pulse rectifiers are fed from delta and polygon primary windings with different turns ratio and phase shifted by 5 degrees. Under the proposed control scheme, one rectifier is kept at nominal output voltage, and the other one is phase controlled to control the load's current. The proposed strategy greatly improves the rectifier's performance, reducing its reactive power maximum demand by 62% compared to conventional rectifiers and, therefore, reduces the input filters power rating also by 62%, This is accomplished while keeping the input power factor above 0.95 throughout the whole operating range. Further, the converter's reactive power consumption presents a low varying characteristic, allowing it to use a fixed tilter, even when operating from a power system not capable of withstanding large reactive power variations, Finally, it presents a harmonic current distortion comparable to conventional 12-pulse high- current rectifiers, This paper presents the design and optimization procedure of the rectifying system. A 2.5-kVA laboratory prototype was used to validate the converter model, later employed in evaluating the converter operating in a 10.5-MVA copper electrowinning facility. The results obtained confirm the advantages of the proposed converter and its control strategy.