The growth of the automotive EV battery market could be lucrative for resourceful manufacturers in the United States. With gigafactories in Nevada, New York and Texas, and another proposed for Georgia, the pace of construction is picking up, but still trails the growth in Europe and China.
Just as important as the speed of construction, however, is compliance.
From air quality on the factory floor to combustible dust management systems for the various production processes, the guidelines, standards, and regulations for EV battery manufacturing continue to evolve with the industry.
With the latest technology and equipment, revolutionary procedures, the use of potentially hazardous raw materials along with the dust, fumes, and particulates generated during the manufacturing process, more stringent standards are in everyone’s best interest.
The best time to address these important issues is long before manufacturing ever begins – during the initial design and construction phases.
Collect and Control Particulates
There are points throughout the EV battery manufacturing process, where potentially dangerous particles could be released into the air, including dust from lithium, cadmium, nickel, cobalt, and aluminum. Weld fumes generated in the process are also considered toxic and most have compliance standards associated with them.
Dust from some materials can be flammable or combustible, which must be properly identified through a Dust Hazard Analysis and then managed accordingly given the results of your DHA.
There are several points in in the manufacturing process where these issues must be identified and managed, including:
- Mixing
- Coating
- Material Handling
- Machining
- Metalworking
- Drying
- Welding
- Assembly
- Recycling
Gigafactory designs should include effective solutions to properly collect and control particulates at each stage of the manufacturing process.
Effective dust control systems – from hoods and benches to extractors and collectors – is critical for meeting OSHA standards, maintaining a clean and safe work environment, and staying compliant with regulatory requirements governing fumes, dust, and particulates in the workplace.
Planning Helps You Manage Risks
A gigafactory needs to have the highest standards in place to ensure that the batteries produced are made correctly and work properly. That means the facility and all its equipment needs to filter dust and other particulates that could potentially impact the quality of the batteries.
As noted by Bob Galyen, a globally recognized expert in battery technology, "It’s important to understand all the processes in EV battery manufacturing to ensure proper air handling. For example, what needs to be mitigated and how, what areas of the plant have positive or negative air pressure, and what areas have noxious airborne chemicals? There is little room for error when safety is at stake."
Therefore, choosing and installing an effective collection system for dust, fume and mist starts with a thorough review of the facility’s hazards, intended layout and processes. Consider these factors:
- Contaminant – What material are you trying to collect, and does it pose any hazards?
- Work Layout – Will the area be open or divided into individual cells? Is the ability to reconfigure the layout important?
- Production Area – Are there physical space limitations due to size or existing structures?
- Production Volume – Given projected/possible expansion, what is the maximum anticipated production volume?
- Uptime – Which system offers the most efficient collection with minimal downtime for filter change-outs, cleaning, and maintenance?
Invest Upfront
While it’s possible to retrofit a facility with the proper filtration equipment post-construction, it is far easier – and more cost-effective – to do so upfront at the onset of the project.
"Many times, an air handling system is large and heavy, and if not planned in advance, a building may not have the right structure for installation of the equipment," says Galyen.
Just as highly automated, fast-paced EV battery manufacturing processes are designed to maximize productivity, a factory’s dust, fume, and mist collection systems need to keep pace. By investing in and maintaining reliable collection equipment designed to a facility’s specific requirements, process owners can expect effective filtration and a compliant work environment.
Seek Consultative Guidance, Support and Service
Whether you’re looking for a turnkey dust control solution or just need some help getting started, engage specialists who will work with you to:
- Conduct an appropriate Dust Hazard Analysis
- Implement the proper ventilation and filtration systems for your plant to reduce the release of concerning particles, including combustible dust, into the air
- Address regulatory compliance within your specific production facility
- Provide support and guidance, ensuring your equipment is up and running
In addition, it can help to follow current EV battery research and initiatives like NHTSA’s Battery Safety Initiative for Electric Vehicles that coordinates research and other activities to address safety risks relating to batteries in electric vehicles. Efforts such as these can identify and raise awareness of potential safety risks as technology advances.
Safety at Every Step
As a growing market and viable green energy solution, EV battery technology is here to stay, but only if the manufacture, storage, use, and recycling remains compliant and appropriate given the various risks. For gigafactories, that starts with implementing optimized dust control solutions at all stages – from the mixing of cathode and anode materials to coating, machining, welding, and assembly.
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