AntistaticPneumaticConveyingofLiBPowders,WroclawPL

Antistatic Pneumatic Conveying of LiB Powders, Wroclaw PL

Subtitle: Safe and Efficient Handling of Lithium Battery Raw Materials in Poland

Keywords: Pneumatic Conveying Case, European Pneumatic Conveying, Antistatic Pneumatic Conveying

This project report describes an advanced pneumatic conveying installation completed by Shandong Headpowder Engineering Co., Ltd., known as headpowder, for a lithium battery raw material producer in Wroclaw, Poland. The facility processes and transports fine powders used in the manufacture of lithium-ion batteries. The main objective was to deliver a reliable, explosion-proof, and antistatic conveying line that could safely handle these sensitive materials while meeting high European production standards and local safety regulations.

Wroclaw, a dynamic city in Lower Silesia, has become an important center for the European battery industry. The customer operates a modern plant producing cathode and anode precursor powders. These materials are very fine, often with particle sizes below ten micrometers, and they have a strong tendency to generate electrostatic charges during friction and impact. If these charges are not neutralized, they can cause powder adhesion, flow irregularities, and dangerous electrostatic discharges. Because the powders can form explosive dust clouds, every component of the conveying system must be carefully designed, grounded, and certified for hazardous areas.

To address these challenges, headpowder designed a closed-loop dense phase pneumatic conveying system. Dense phase conveying uses a low gas velocity and a high solid-to-gas ratio, which significantly reduces particle-to-particle and particle-to-wall collisions. This minimizes both electrostatic generation and mechanical degradation. The system operates with a carefully selected pressure level and pulse control to move powder smoothly in plugs, preventing blockages and ensuring uniform flow. The conveying pipeline is arranged with a minimum number of bends, and all bends are of the long-radius type to further reduce friction and charge generation.

The designed system covers a total conveying distance of approximately 150 meters, with a production capacity of two tons per hour. It includes three receiving hoppers, two rotary feeders, one main conveying line, and one distribution manifold with nine automatic discharge valves. The system is configured to convey multiple material grades alternately, and the cleaning sequence between product changes is fully programmable. This flexibility enables the customer to produce different battery material recipes on the same line without cross-contamination. Every part of the system is made from high-grade stainless steel with a polished internal finish to provide a smooth surface and easy cleaning.

The entire conveying route is made of stainless steel pipes with a polished internal finish. The piping is equipped with conductive grounding wires at every flange and joint. All gaskets are made of conductive silicone. The system includes antistatic rotary valves, bellows, sight glasses, and flexible connections. Each section is grounded to a central earth busbar with resistance less than one ohm. This robust grounding path safely dissipates any accumulated charge to ground, eliminating the possibility of spark generation. In addition, the system is equipped with continuous electrostatic charge monitoring and alarms that immediately alert operators if any abnormal charge level is detected.

Safety is further enhanced by using nitrogen as the conveying medium instead of compressed air. The nitrogen is supplied from a liquid nitrogen tank and vaporized through a control skid. The system maintains an oxygen level below five percent in all parts of the conveying line and silos. Oxygen sensors are installed at critical locations, and the interlocking control system automatically initiates a nitrogen purge and stops powder feeding if oxygen concentration rises above the preset limit. This inert atmosphere makes dust ignition impossible even under abnormal conditions. The system also includes explosion relief panels on the silos and filters as a secondary safety measure.

The system is fully automated through a PLC-based control panel integrated with the plant's distributed control system. The control logic manages the sequence of feeding, conveying, filtering, and discharging. It also monitors pressure, flow rate, and static charge levels in real time. Data recording and remote access allow the customer's operators to supervise the entire process from a central control room. The system includes comprehensive alarms and emergency shutdown functions to ensure safe operation in all situations. All electrical components are ATEX-certified and suitable for use in potentially explosive dust atmospheres.

Since commissioning, the Wroclaw installation has operated with exceptional performance. The conveying capacity consistently meets the design requirements, and no incidents of dust leakage or electrostatic discharge have been recorded. The product quality has improved because the gentle conveying action avoids particle breakage and keeps the powder free-flowing. Maintenance requirements are low, and the system has become a benchmark for other production lines in the same plant. The customer also reported a significant reduction in downtime and a cleaner working environment compared with their previous mechanical conveying methods.

This successful European project showcases headpowder's expertise in antistatic pneumatic conveying and its commitment to meeting international safety standards. Shandong Headpowder Engineering Co., Ltd., headquartered in Shandong, China, specializes in designing, manufacturing, and installing complete pneumatic conveying systems for powder and bulk materials. The company has delivered numerous projects in Europe, Asia, and the Americas, particularly in the chemical, new energy, and food industries. With a strong focus on innovation, safety, and customer satisfaction, headpowder has earned a reputation as a reliable partner for complex powder handling challenges.

For project inquiries and technical consultation, please contact General Manager Zhang. WeChat: 15662777102. Headpowder welcomes the opportunity to discuss your specific material characteristics, process requirements, and plant conditions to provide a tailored conveying solution. Whether you need a complete system or a single component upgrade, the engineering team is ready to support your business with detailed proposals and professional service. With proven project experience across Europe and beyond, headpowder is your trusted partner for high-quality, safe, and efficient pneumatic conveying systems.