Plating, Anodizing & Surface Treatment worked example

Rectifier Energy Cost at 99% rectifier dc conversion efficiency: a worked example

Push rectifier dc conversion efficiency up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when sizing the power bill behind a plating or anodizing line and attributing rectifier energy to a job.

The inputs for this scenario

  • Rectifier energy drawn per run: 320 kWh (unchanged)
  • Utility electricity rate: 0.14 $/kWh (unchanged)
  • Rectifier DC conversion efficiency: 99 % (raised for this scenario; the documented default is 88)
  • Cooling and standby load adder: 22 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Energy cost = kWh x electricity rate x rectifier efficiency% + cooling and standby adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 64.77 $ for total rectifier energy cost, the number this scenario is built around.
  • At this operating point the engine returns 0.2 $ / piece for rectifier energy cost per unit.
  • At this operating point the engine returns 42.77 $ for variable rectifier energy cost.
  • At this operating point the engine returns 22 $ for fixed rectifier energy cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where rectifier dc conversion efficiency sits at 88% and the headline result is 60.02 $, this scenario comes in 7.92% above the baseline at 64.77 $.
  • It computes the total electricity cost of a rectifier run by scaling energy drawn by your rate and efficiency, then adding a fixed cooling and standby load, and it back-solves the cost per kWh actually delivered. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total rectifier energy cost: 64.77 $ (headline result)
  • Rectifier energy cost per unit: 0.2 $ / piece
  • Variable rectifier energy cost: 42.77 $
  • Fixed rectifier energy cost adder: 22 $

Run it with your numbers

  • Every input above is editable in the live Rectifier Energy Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.