Powder handling by production battery
As the world increasingly moves towards renewable energy, batteries have become an essential part of energy storage. However, the production of high-quality batteries requires a complex process that involves several stages of production, including bulk material processing. Powder processing plays a crucial role in battery production as it involves the transportation, storage and handling of powder materials used in battery electrodes.
Processing also requires a delicate balance between ensuring their purity, preventing (cross)contamination and maintaining optimal conditions for their physical and chemical properties. Moreover, the trend towards electric mobility and energy storage is driving demand for lithium and other raw materials such as cobalt, nickel and manganese, especially in battery production. In the demanding battery production chain, the supply of raw materials is the first but important step for the quality of the final product.
Again, powder handling plays an important role in battery life and performance. In addition to explosive protection measures, containment aspects must also be taken into account.
Massproduction of battery
Plant Partner realises and supplies state-of-the-art discharge, transport and metering technologies for the production of various battery components. Central is the continuous and accurate supply of raw materials for the production of cathodes and anodes. The protection of users and the product is central. Our client is a well-known battery manufacturer in Germany. The installed combination system consists of an anode and cathode lines. Both lines consist of two separate and independent subsystems. Essentially the same process is carried out in each subsystem, starting with the feeding stations. In the system, powder components are supplied, transported and dosed into a customer-supplied mixing vessel. The powder is then used in subsequent process steps to produce electrode paste for lithium-ion battery electrodes. A total of two mixing stations with corresponding product feed were supplied.
Functional
Key components for anode and cathode materials are loaded in dust-free big bag unloading stations. Big Holder unloading stations essentially consist of four components: a connection system as the core component for safe unloading, a support table for securing suspended loads, a frame for mounting the connection system and a lifting device. The big bag unloading stations implemented at the customer's site are also equipped with a clod breaker, which removes agglomerates and lumps before transporting and dosing.
First, the big bag is connected to the endless liner connection system for closed product handling. This system is characterised by a defined, safe handling process with a logical sequence of operations in a few steps, allowing powders to be handled easily, ergonomically and safely. Even during big bag changes, the system remains closed to the environment, so no product dust can escape. This enables compliance with the required OEB-4 level for NMC products.
The materials required for battery production, such as soot and graphite, are relatively non-critical to the operator and are usually processed without OEB-level specifications. However, for emptying these products, the endless liner system for OEB level 4 was used, mainly for environmental hygiene reasons and to avoid possible cross-contamination.
Small quantities of these materials are delivered in bags of various sizes and are emptied dust-free. The bags are fed through a feed and seal system to an unloading station with glove ports. The bags are then opened and emptied through glove ports. The empty bags are unloaded through a side entrance to a liner.
A ball valve suction shoe with an agitator under the glove box transports the product to the pneumatic conveying system, ensuring consistent bulk material quality and particle size distribution.
In the next step, a vacuum conveyor (PCC) transports the powder to the dosing station. The ProClean Conveyor PCC is a highly efficient, highly flexible pneumatic conveyor designed for long transport distances and the safe transport of explosive or toxic materials. A separate conveyor system is used for each product. The conveyors also serve as storage vessels from which dosing is done into the customer's mixing vessel. The required accuracy was easy to achieve (primary weighing, withdrawal modelling).
If several materials are transported in a mixing vessel, this is done sequentially according to a predefined recipe. Up to three different solids can be transported in the mobile mixing vessel. The number of products and means of transport can be increased if necessary. After each individual dosing, the dosing result in the mixing vessel is checked by check weighing. The mixing vessel is located in an extraction booth and is closed with a pneumatically operated lid. The lid is fitted with connections for components and ventilation.
Then, in the customer's mixer, the so-called electrode paste is produced by adding liquid. In the further process, this paste is applied to a metal substrate, dried and cut. Separator films made of porous plastics are applied between the two electrodes to prevent short circuits. In the final step, the electrodes and separators are stacked in layers and placed in an enclosure filled with an electrolyte that transports ions between the electrodes. Finally, the enclosure is sealed to prevent electrolyte leakage.
Recycling proces
De productie van batterijen is niet alleen een complex proces, maar recycling is ook een belangrijk aspect bij het verminderen van de milieu-impact van gevaarlijke chemicaliën. Er zijn echter verschillende uitdagingen die het recyclen van batterijen bemoeilijken. Roet is bijvoorbeeld zowel een nuttige als potentieel gevaarlijke stof bij inademing. De fijne deeltjes kunnen in de longen terechtkomen en ademhalingsproblemen veroorzaken. Daarom moeten veiligheidsmaatregelen worden genomen bij het gebruik van carbon black.
Carbon black kan worden verkregen uit gebruikte batterijen via een recyclingproces dat pyrolyse wordt genoemd. Pyrolyse is de thermische afbraak van organische materialen in een zuurstofvrije omgeving. In het geval van batterijen worden ze eerst mechanisch geplet en gedemonteerd in hun afzonderlijke componenten. De batterijdelen worden vervolgens onder zuurstofvrije omstandigheden in een oven verwarmd. Door de hitte worden de organische materialen in de batterij afgebroken, wat resulteert in een mengsel van vloeibare en gasvormige componenten en roet. Het resulterende mengsel wordt vervolgens in verschillende stappen verwerkt om het roet van andere componenten te scheiden en te zuiveren. Het teruggewonnen carbon black kan worden gebruikt in andere toepassingen, zoals de productie van rubber en plastic, of worden hergebruikt bij de productie van batterijen. Bij recycling worden ook andere materialen teruggewonnen, zoals lithium, kobalt, nikkel en draagfolies van koper of aluminium. Om deze producten veilig af te vullen en in de laatste stap klaar te maken voor transport, biedt Plant Partner meerdere containment transport- en/of vulstations aan.
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