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Mixing An Electrifying Seal Solution for the Cathode Powder Industry

Mixing An Electrifying Seal Solution for the Cathode Powder Industry

For the moment, at least, it looks like the future of batteries for electric vehicles belongs to the cathode powder industry. Innovations in this area are moving toward solid-state powder-composite batteries with much thicker electrode structures and, therefore, much higher capacity. The upshot: electric vehicles with far greater range.

Preparing for Growing Powder Demand

The need for cathode powder will most likely grow rapidly, and powder manufacturers need to be ready to meet the demand. So what could stand in the way?

One answer to this question is probably not top of mind, but it should be: mixer failures resulting from seal failure. Why? Because mixers and blenders failures create:

  • Potential hazards to employees
  • Potential hazards to the environment
  • High costs in time and money
  • Failure to keep up with demand and, therefore, loss of business 

The time to evaluate and upgrade mixer seals is now before the demand increases. Installing CinchSeal rotary shaft seals helps ensure that mixers and blenders continue operating at peak efficiency.

High pressure rotary shaft seals

Why CinchSeal Rotary Shaft Seals?

In chemical plants, mixer and blender failures happen for several reasons, but the main causes include:

  • Premature bearing failure
  • Irreversible damage to shafts
  • Expensive battery powder leakage
  • Toxic environment contamination 

Premature Bearing Failure

Contamination is one of the leading causes of bearing failure. This happens when contaminants infiltrate the mixer bearing housing, resulting in high vibration and wear. Lack of lubrication,  abrasive battery mixing material, misalignment, too tight or too loose fit are also major reasons of the bearing wear and tear. The problem should be addressed by upgrading the seals when the bearings are changed.

Irreversible Damage to Shafts

Here the issue is friction between the stationary lip seal or mechanical packing and rotating shaft. Eventually, it wears and tears the shaft and causes leakage and failure. These sealing methods are still in wide use but CinchSeal rotary shaft seals offer a better solution.

Expensive Battery Powder Leakage

The cathode and other raw materials used in mixing the battery powder and slurry are more than a half of the Li-ion cell cost. They are quite expensive and can’t be recovered if a mixing equipment fails. Each year, they cost battery industry millions of dollars in lost product.

Toxic Environment Contamination

Leakage of battery dust is toxic and can contaminate working areas and cause health hazards. Moreover, this type of raw material is difficult to get rid of. Lack of uniform regulatory policy on their disposal means that lithium batteries may substantially contribute to environmental pollution and adverse human health effects.

Split rotary shaft seals

The CinchSeal solution

CinchSeal rotary shaft seals effectively solve these four leading causes of pump failure. They also significantly reduce the maintenance time and costs.

Here are the four causes again, in reverse order, and how CinchSeal rotary seals address them:

Premature Bearing Failure

  • The CinchSeal self-adjusting design does not allow contamination build-up in the bearing housing
  • The self-lubricating seal enables a dry-running seal operation, decreasing its wear and tear.

Irreversible Damage to Shafts

  • CinchSeal rotary seals eliminate damage from rubbing. An elastomer that spins with the shaft prevents friction.
  • Moreover, it can tolerate shaft misalignment of up to ¼ inch, common in bulk-handling equipment, without losing its seal

Expensive Battery Powder Leakage

  • An air barrier created by purging prevents the product from entering the seal
  • It also develops a force that pushes the rotating faces outward against the stationary faces and creates a tighter seal
  • Cooling off rotating seal faces reduces friction-generated heat and prolongs the useful life of the seal

Toxic Environment Contamination

Two features of every CinchSeal rotary shaft seal help stop product leakage and environment contamination:

  • Larger shaft/seal interface surface
  • FDA-approved silicon elastomer and PTFE rotor cups

Less Maintenance, Fewer Replacements

CinchSeal rotary shaft seals last longer. They need less maintenance, which means time and cost savings. And they don’t have to be replaced as often. When it is necessary, only internal parts – elastomer and rotor cups – need to be replaced. Changing them out is also a simple process. 

This simplicity is especially evident in CinchSeal split rotary shaft seals made for harsh environments, like those found in chemical plants. Split seals offer a number of advantages:

  • Stainless steel that stands up to harsh working conditions
  • Split rotary shaft seals that make conversion and installation easy
  • Easy disassembly to make batch and frequent cleanings a breeze

The Seal choice is a Cinch

To sum it up, here’s why CinchSeal rotary shaft seals make the most sense of producers of cathode powder:

  • They solve four main causes of mixer and blender failures: bearing failure, damage to shafts, product leakage, and product and environment contamination.
  • They require maintenance and replacement less often, and, in both cases, the process is much simpler.
  • They offer an economically superior solution to failures that can cause harm to people and the environment as well the bottom line.

For over 25 years, CinchSeal has been a leading manufacturer of rotary shaft seals for screw conveyors, ribbon blenders, and all kinds of bulk-handling equipment. CinchSeal products serve as replacements and major upgrades that make the need for machine replacement less likely.

More information is available by contacting CinchSeal. Quotes and drawings are guaranteed to be available in 24 hours. Custom engineering usually takes 10 days.

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