Raw Material Loss Reduction in Secondary Battery Manufacturing Process

The loss of raw materials in the secondary battery manufacturing process has become a serious issue across the industry. A major cathode material manufacturer reported that the poor performance of their factory's dust collectors was causing them to waste approximately $200,000 worth of expensive raw materials every month.

Predictive maintenance in the secondary battery manufacturing process has been significantly improved by utilizing dust monitors. This innovative approach makes it possible to minimize raw material losses and increase production efficiency.

The dust monitor continuously monitors dust leakage from the dust collector and provides real-time data, which provides the following benefits:

• Proactive maintenance: Instead of relying on traditional scheduled inspections, maintenance can be performed based on the actual condition of the equipment. This reduces unnecessary inspections and allows you to take the right action when it is really needed.
• Reduced operational costs: Predictive maintenance prevents unplanned downtime and extends the lifespan of equipment, a key factor in improving the overall cost-efficiency of the secondary battery manufacturing process.
• Preventing raw material loss: Dust monitors prevent the loss of raw materials by monitoring filter degradation and wear trends. This is especially important in the production of expensive secondary battery cathode materials.
• Environmental protection : Early detection of dust leaks prevents air emissions and ensures compliance with environmental regulations.

In one real-world case, a metal processing manufacturer in the Netherlands installed a remote monitoring system called GoldLink Connect on eight Camfil MF-U dust collection systems. The system enabled them to analyse real-time performance data on a user-friendly dashboard and make adjustments if necessary.

The dust monitor is relatively easy to install and does not require any special knowledge or complicated adjustments. This is expected to promote the adoption of predictive maintenance throughout the secondary battery manufacturing industry, improving productivity and reducing the environmental impact.

 

The closed-loop recycling system is an innovative approach that could significantly improve sustainability in the secondary battery industry. It involves dismantling used batteries and reusing their raw materials in the production of new batteries, minimizing resource waste. Key benefits include:

• Reduce demand for mining raw materials by about 25% and reduce CO2 emissions from secondary batteries
• Conserve valuable resources and reduce negative impacts on the environment
• Reduce battery manufacturing costs and improve industrial economics
• Reduce reliance on politically unstable regions and improve supply chain stability

Major companies such as BMW and BASF have already adopted this system, and it is scheduled to be rolled out in North America by 2026, raising hopes that closed-loop recycling will become widespread throughout the secondary battery industry.

Lithium recovery by hydrometallurgy is an innovative method to efficiently extract valuable materials from spent lithium-ion batteries. This method offers the following advantages over conventional pyrometallurgy:

• Low energy consumption and 74% reduction in greenhouse gas emissions1
• Avoids harmful chemicals and uses 97% less water
• Metals such as lithium, nickel, cobalt, and manganese can be recovered with a purity of over 99%
• Metals are dissolved using an acidic solution and then separated and refined through selective chemical reactions, making it suitable for use with a wide range of battery types.

With widespread adoption of this technology, it is predicted that by 2040, 53% of global lithium demand could be met through recycling of used batteries. This represents a major step towards significantly improving the sustainability of the secondary battery industry and reducing its reliance on mining of raw materials.

Real-time dust data analysis is a key element in combating raw material losses in the secondary battery manufacturing process. Utilizing advanced data analysis techniques can provide the following benefits:

• Building predictive models: Time series and trend analysis can be used to forecast future dust concentrations so that proactive measures can be taken.
• Faster anomaly detection: By continuously monitoring real - time data and using statistical techniques to immediately detect deviations from normal ranges, loss of raw materials can be minimized.
• Comprehensive analysis through data integration: By integrating data from multiple sensors and combining it with information on environmental factors and production processes, the root causes of dust generation can be identified and effective countermeasures can be developed.

Utilizing these analytical techniques will make it possible to improve the efficiency of the secondary battery manufacturing process and reduce raw material waste, thereby contributing to improved productivity and reduced environmental impact.