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Electrolysis is an important way to produce manganese metal, but the low current efficiency and random growth of dendrites have always been challenging problems for enterprises. The lack of understanding of the dynamic system during the electrolysis process is the main reason for the accurate control of the electrolysis process. Based on this consideration, a new four-dimensional continuous hyperchaotic system with high Lyapunov exponents is designed. The amplitude control, frequency modulation, and offset boosting of the hyperchaotic system are obtained through the selection of feedback term. A circuit simulation and corresponding simplified circuit are established. In addition, the actual hyperchaotic circuit is applied to the manganese electrolysis process through the self-designed current amplification module (the amplification of w signal is realized by the offset boosting control). The experimental results of the hyperchaotic electrolysis of metal manganese showed that the hyperchaotic current can delay the occurrence time of electrochemical oscillation, and reduce the generation of cathode metal manganese dendrites. Furthermore, the results show that the hyperchaotic current can enhance the current efficiency and reduce the energy consumption. Based on the new experiment, it is suggested that the formation of anodic porous structures, whose primary phase compositions were PbSO4, MnO2, and Mn2O3, is one factor for the occurrence of electrochemical oscillations, while the conversion between Mn 3 + and Mn 4 + is another main factor for the mutation of electrochemical signal (manganese autocatalysis). [ABSTRACT FROM AUTHOR]