During the production of lithium battery cathode materials, the particle integrity of the powder transport stage directly affects the electrochemical performance and consistency of the final product. To meet the actual production line needs of a lithium battery materials company in Ji'an, Jiangxi, Head Powder provided a dedicated low-crushing conveying system, successfully solving the industry problem of cathode powder being prone to fragmentation and micropowder generation during transportation.

Case Summary

This case is located in Ji'an, Jiangxi. The client is a company specializing in the production of lithium battery cathode materials. Its production line requires transporting cathode powders such as lithium iron phosphate and ternary materials from the storage silo to subsequent processes. Traditional pneumatic conveying or mechanical lifting methods cause significant impact on powder particles, resulting in a high crushing rate and affecting product quality and batch stability. Head Powder designed and implemented a customized low-crushing conveying solution tailored to the process parameters and material characteristics of this production line.

Customer pain points

Customers face multiple challenges in production: first, traditional conveying equipment experiences high-speed shear and impact at bends and discharge ports, causing cathode powder particles to break and increasing micropowder content; Second, the crushed fine powder easily generates dust, polluting the workshop environment and causing material loss; Third, as the powder particle size distribution widens, the uniformity of subsequent coating and roll pressing processes decreases, ultimately affecting battery capacity and cycle life. In addition, the original conveying system consumed more energy and required frequent maintenance, which constrained the stability of continuous production.

Product advantages

To address these pain points, Head Powder's low-crushing conveying solution has the following core capabilities:

• Low shear force design: Uses optimized airflow velocity and pipe geometry, combined with dedicated bending curvature and buffering devices, reducing the impact force on particles during conveying to a relatively low level, with a measured crushing rate about 70% lower than traditional methods.
• Fully sealed and dust-free transport: The system adopts a negative pressure sealed circulation design, combined with a high-efficiency filter dust removal device, achieving zero powder leakage during conveying. Workshop dust concentration meets environmental protection requirements while reducing material loss.
• Relatively accurate regulation and intelligent monitoring: Equipped with variable frequency adjustment and pressure sensors, allowing real-time adjustment of conveying speed and gas-solid ratio according to powder characteristics; An integrated online monitoring system provides early warnings on pellet crushing trends, facilitating maintenance and management.
• Stable and efficient continuous operation: Key components use wear-resistant materials and optimized sealing structures to reduce downtime and maintenance frequency; The system can be adapted to different cathode powders (such as lithium iron phosphate, lithium cobalt oxide, etc.), enabling rapid switching between multiple products and improving overall production line operation efficiency.

This solution has been operating normally on the Ji'an production line in Jiangxi for over 12 months, with significant improvements in cathode powder particle integrity, a product pass rate of about 5% higher for customers, and workshop maintenance costs reduced by about 30%, making it a reliable practice for low-crushing conveying in the lithium battery cathode material industry.