Is power factor the same as conversion efficiency?

No, enter DC energy divided by AC input energy. Power factor concerns apparent versus real AC power and cannot replace that energy ratio.

Can the energized interval be zero?

Yes, zero hours produces zero DC and AC energy. The total then equals the separately entered auxiliary expense.

Should I use the rectifier current setpoint?

Use measured average DC power over the interval. A setpoint does not capture changing voltage, current or duty during processing.

Where does chiller electricity belong?

Put it in auxiliary expense only when it lies outside the rectifier AC energy boundary. Use the actual allocated charge for this job.

Plating, Anodizing & Surface Treatment calculator

Rectifier Energy Cost From DC Output and AC Draw

Find job electricity cost from rectifier DC output and AC conversion losses. Enter interval power, efficiency, duration, allocation and invoice charges.

What this calculator does

Convert measured DC output into AC energy draw, allocate its utility charge and add separately booked auxiliary expense.

Formula used

DC energy = average DC output × energized hours
AC draw = DC energy ÷ (conversion efficiency ÷ 100)
Allocated AC energy = AC draw × (job allocation ÷ 100)
Utility charge = allocated AC energy × electricity rate
Rectifier energy cost = utility charge + separate auxiliary expense

Inputs explained

Average DC Output: Average delivered DC power from the operating interval meter.
AC-To-DC Energy Efficiency: Measured DC output energy divided by AC input energy.
Energized Interval: Duration matching the average DC power measurement.
Job Energy Allocation: Recorded share of rectifier AC energy assigned to this job.
Utility Energy Rate: Invoice energy charge for this interval.
Separate Auxiliary Expense: Cooling and standby expense outside the energized rectifier energy boundary.

How to use the result

Best suited to rectifier job energy allocation, separate cooling expense reconciliation.
Demand charges require an actual allocation in the utility rate or separate auxiliary expense. Nameplate output alone does not establish actual energy consumption.

Current U.S. benchmarks

As of Jul 2026, industrial electricity averages 9.8 cents per kWh across the U.S. (EIA), up 4.7% from a year earlier. State averages range widely, so plants should confirm against their own tariff.
The producer price index for industrial chemicals stands at 336.006 (BLS, Aug 2026), up 13.3% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The U.S. has 14,543 chemical manufacturing establishments employing about 911,245 workers (Census County Business Patterns, 2023).

Common questions

Is power factor the same as conversion efficiency? No, enter DC energy divided by AC input energy. Power factor concerns apparent versus real AC power and cannot replace that energy ratio.
Can the energized interval be zero? Yes, zero hours produces zero DC and AC energy. The total then equals the separately entered auxiliary expense.
Should I use the rectifier current setpoint? Use measured average DC power over the interval. A setpoint does not capture changing voltage, current or duty during processing.
Where does chiller electricity belong? Put it in auxiliary expense only when it lies outside the rectifier AC energy boundary. Use the actual allocated charge for this job.

Last reviewed 2026-10-06.