Bulk Metallic Powder Debagging & Blending
Project Overview
Bulk metallic and chemical powder material unbagging and mixing is streamlined with Peveril Xtractor Automated Bag Unloading System. The result was a safer and cleaner work area that improves the process flow and quality control
Challenge
This well-established lead smelter and battery manufacturer has innovated over the years inline with evolving battery technology and the increasing demand for metal recycling. The production growth was leading to inefficiencies in the receipt and mixing of powdered material used in their next-generation, energy-dense lithium-sulphur batteries.
The result of this rapid change in demand and material was an increase in manual handling and the need to mix chemicals within the refining area, making material integrity and quality control a challenge.
- Tote bag powder unloading & blending
- 10,000kg/hr production flow
- Blending ratio 0.5% accuracy
- Increase capacity, safety, and efficiency
Solution
Peveril, the dry-material processing side of Atlantic Pumps, conducted a site survey and processing audit to gain a comprehensive understanding of the requirements and challenges. The final proposal agreed on saw the installation of an automated bulk bag handling, de-bagging, and transfer system. Two powered ingredients (such as iron pyrite and sulphur) are loaded into the system, and are then blended at the correct ratio as they enter the transportation hopper. The primary mix ratio is controlled by loss-in-weight load cells, and a pre-set program which synchronises the bulk ingredient unloading. An enclosed screw conveyor transports the material into the furnace melting pot, with a 10,000kg per hour feed rate capacity. Finally, dust barriers were fitted to the support frame to contain dust and prevent product contamination.
Results
The new system entirely eliminated a number of manual processes, which increased capacity while improving health & safety, enabling greater quality control and improving general ‘house-keeping’.
- Open mixing eliminated, creating a safer and more pleasant work environment.
- Improved dosing and ratio control, with accuracy now within 0.5%
- Freeing up space in the already crowded refinery area and reducing the movement of personnel from zone to zone.
- Manual handling eliminated, with less exposure to dust and the hazards associated with proximity to the furnace.
- Reduced FLT and lifting equipment movements.
- Batches of pre-mixed reagents can be made in advance, helping to address peak demand periods and planned maintenance downtime.
- Efficiency savings – no lengthy labour-intensive processes, such as manually mixing reagents.