Bulk handling in the battery industry: containment, dosing and transport of active materials
The battery industry — particularly the production of lithium-ion batteries for electric vehicles and energy storage — works with a range of powders and slurries that place very high demands on containment, dosing accuracy and cross-contamination prevention. Cathode active materials (CAM) such as NMC, NCA and LFP are toxic and costly. A proper bulk handling setup is therefore not a luxury but a production necessity.
Active materials in battery production: what makes them special?
Cathode active materials contain lithium, nickel, manganese and cobalt. They are toxic upon inhalation and skin contact, and extremely costly (€15–40/kg depending on type). Anode materials such as graphite and silicon are less toxic but flammable. For all active materials, the following applies:
- Minimal operator exposure (OEB approach)
- Maximum material yield (no losses during transfer)
- Cross-contamination prevention during product changeover
- Protection against moisture (hygroscopic behaviour of Li salts)
Big bag handling for CAM and anode material
Cathode active materials are typically supplied in big bags of 500–1000 kg. A contained big bag discharge via HECHT's LAS/AAS system connects to the bag inlet without dust emission. For elevated containment requirements (OEB 3–4), the endless liner system provides a closed transfer path from bag to process installation.
Benefits of endless liner for battery materials:
- No direct exposure during bag changeover
- Dust-free connection during empty bag removal
- Easy-to-clean system (no product in the coupling)
Accurate dosing of cathode materials
In electrode production (slurry mixing), the CAM/binder/conductive additive ratio must be maintained precisely. A deviation of >1% directly affects battery capacity and cycle life. Hecht Technology supplies:
- Gravimetric dosing screws (loss-in-weight) for ±0.2% accuracy
- Flexible Dosing System FDS for multi-component dosing in recipe processes
- Weighing decouplers for isolation from process vibrations
Pneumatic transport: dry room compatible
Battery production typically takes place in dry rooms (dew point <-40°C). Pneumatic transport systems for battery materials must:
- Be gas-tight (no air leaks = no moisture ingress)
- Be compatible with dry compressed air or inert gas (N₂)
- Be cleanable without wet cleaning (dry or vacuum)
Hecht's dense-phase transport lines with rotary valves and contained connections meet dry room requirements.
Containment when switching battery chemistry
Manufacturers producing multiple battery chemistries (NMC vs. LFP vs. NCA) must strictly exclude cross-contamination. Hecht's single-use endless liner systems and dedicated transfer sleeves enable product changeover without residual contamination in the process installation.
Hecht Technology: bulk handling for the battery industry
Hecht Technology supplies complete bulk handling systems for battery materials: from contained big bag discharge, through accurate dosing, to pneumatic transport in dry room environments. Our systems are suitable for NMC, NCA, LFP, graphite and silicon anodes.
More information: Big bag discharge systems, Dosing screws, Flexible Dosing System FDS.
Conclusion
The battery industry places unique demands on bulk handling: toxic and costly active materials, extreme dry room requirements and strict cross-contamination prevention. Hecht Technology offers proven technology for every step of the material flow in battery production.