Case Study: From Challenges to Clarity: Advanced Graphite Powder Grading with Sivtek Vibro Separator

Overview

Graphite powder plays a vital role in a variety of industries, such as battery production, electrode manufacturing, lubricants, coatings, and conductive materials. Being one of the softest natural forms of carbon, graphite is known for its outstanding electrical conductivity and chemical stability. Here we discuss how one of the highest producers of graphite electrodes solved a common industrial problem of powder grading due to the inability to consistently and precisely grade powders using the Sivtek® Vibro Separator.

This company, a significant player in the mineral and metal sector, needed a highly efficient and accurate screening system to uphold the quality standards for graphite powder used in electrode production. Galaxy Sivtek’s Vibro Separator was introduced into their process line to optimize the screening and classification stages, ensuring uniform particle distribution and improved production outcomes.

Challenges in Graphite Powder Sieving

While graphite powder offers various industrial advantages, it also presents several screening and grading difficulties, particularly in high-volume processing plants:

1. Irregular Particle Sizes
   Post-crushing, graphite might vary considerably in particle size. Lack of a dependable screening system makes it difficult to classify to exactness for downstream applications.
2. Mesh Blockage Due to Fines
   Being flaky and powdery in nature, graphite tends to clog fine mesh screens, affecting material flow and reducing efficiency of screening.
3. Low Throughput Rates
   Further on, conventional sifters and screens are unable to deal with high-density graphite material at large volumes, with the effect of lowering throughput.
4. Electrostatic Behaviour
   The screen surfaces and graphite fines can build-up static charge, which allows the fines to stick to the screen surface and prevents separation.
5. Frequent Cleaning and Downtime
   The sticky nature of graphite requires frequent cleaning of screens and machinery; this results in operational downtime and higher labor costs.
6. Quality Consistency
   Variations in particle size distribution constitute one of the factors affecting the performance of electrodes. Variations in grading lead to performance issues in the final application.

Solution: Sivtek® Vibro Separator Integration

In order to identify the operational challenges, Galaxy Sivtek’s technical team spent time to consider the process used by the client for graphite powder processing. Several trials were conducted at Galaxy Sivtek’s in-house testing facility using the client sample materials. Following the results, the solution was also implemented as given below:

Dual-Deck Vibro Separator Installation

A double-deck Sivtek® Vibro Separator was introduced with mesh configurations of 10# and 100# to classify graphite into three precise grades: coarse, medium, and fine. This gave the client the ability to control particle sizes very carefully right at the initial stage.

Key Features and Benefits:

• Vibrasonic De-Blinding System (VDS)
  To counter mesh clogging due to ultrafine graphite particles, the separator was equipped with VDS. This ultrasonic de-blinding system allows the separation process to continue uninterrupted while improving throughput.
• High-Capacity Design
  The separator, by design, did not compromise the throughput of the ultrafine product with a robust build and optimized vibratory motion.
• 3D Motion for Maximum Efficiency
  The three-dimensional motion of the separation process provides the maximum potential to provide stratification and separation of the graphite without agglomeration.
• Easy Disassembly & Cleaning
  The tool-free disassembly of the unit from the frame provides quick and easy disassembly for cleaning cycles. This feature was highly appreciated by the maintenance team.
• Dust-Tight Operation
  The separator’s dust-proof construction prevented material loss and ensured a clean working environment on account of the fine nature of graphite powder.

Results & Impact

After bringing the Sivtek® Vibro Separator into the mix, the graphite processing facility saw some impressive changes in various operational areas:

• Improved Product Quality: Screening, based on consistent particle sizing, provided better-quality electrodes whose applications adhered to standards.
• Higher Throughput: The VDS, together with multi-deck screening, ensured an increase in processing rate while maintaining accuracy.
• Operational Efficiency: Routine cleaning and maintenance became more streamlined and thus minimized downtime and labor.
• Reduced Material Loss: Better containment and controlled separation minimized graphite waste during processing.
• Ease of Maintenance: The maintenance personnel found the system easy and efficient to maintain on a regular basis.

Final Words

This case underscores the importance of using advanced screening technology like the Sivtek® Vibro Separator for complex applications such as graphite powder grading. When capable of solving some very real problems—with mesh blockage to particle size inconsistency—Galaxy Sivtek has once again shown why it’s a go-to partner in the mineral and metal industry.

Whether you’re dealing with graphite, quartz, or any other sensitive mineral powder, Galaxy Sivtek offers tailor-made solutions that align with your processing goals and regulatory requirements.

Interested in upgrading your graphite processing system?

Contact Galaxy Sivtek for a consultation or book a live trial session to experience the power of the Sivtek® Vibro Separator in action.