The Production Process of Batteries on the Republic of Belarus

In the world practice in the manufacture of batteries has accumulated rich experience. In Belarus, however, battery are imported from Poland, Russia and Ukraine. With the commissioning of own battery factory, a major demand of the domestic market will be provided. What is behind the production of batteries and how it looks in practice?

1AK-GROUP aims at the establishment of a closed production cycle battery in Belarus. The companies included in the Group of companies through vertical integration, will provide different stages of production battery (end product), as well as its promotion in the market.

One of the most important components in the manufacturing of batteries, namely, fine lead and its alloys in the form of lead pigs (ingots) are produced by Belinvesttorg-Splav LLC. The company is cutting waste battery.

Photo 1 - the Building of Belinvesttorg-Splav LLC, Beloozersk

The method of separation of lead-containing raw material is separated from the other components and subjected to melting in a short rotary kiln. Then there is purification of the resulting alloy from impurities.

Photo 2 - Clean lead on Belinvesttorg-Splav LLC, Beloozersk

Prepared according to the melt is poured into the mould, forming lead ingots, which are transported by truck on IPower LLC, where the planned production of lead-acid batteries of different sizes.

Photo 3 - Vintage lead free, products are ready to ship

Ready vintage lead and its alloys are manufactured at Belinvesttorg-Splav LLC Beloozersk and pigs (ingots), and delivered to the plant IPower LLC Brest, where used in the production of a new battery.

This means that IPower LLC does not waste battery and manufacturing fine lead.

Photo 4 - the Building of IPower LLC, Brest district, of FEZ "Brest"

The manufacturing process of batteries at IPower LLC in the short description looks like the following:

The lead oxide is made from fine lead, in the form of lead ingots, method of grinding. Solid lead in the form of lead cylinders loaded in a rotating mill. In the process of abrasion of lead generates heat, the surface oxide layers are erased, revealing underneath clean lead for oxidation. For this process to  IPower LLC installed production line of lead oxide Sanhuan (China).

Picture 5 — production Line lead oxide Sanhuan (China)

The air flow carries the dust into the filter where it is deposited and transported in holding tanks. To reduce emissions of pollutants into the atmosphere by IPower LLC established a three-stage cleaning system: a technological filter, fine filter НЕРА13, the filter is absolute clean.

Of lead ingots in the production line of lead-calcium strip (Sanhuan (China)) is a "slab" from which, passing through rolling rollers, it turns out the tape is of the size required for subsequent fabrication of the grating.

Photo 6 — production Line pigjwc-calcium ribbon (Sanhuan (China))

Then in parallel there are two production process: the manufacture of grills and pastas.

The production lattice is a method of punching (perforation) of lead tape. The finished tape is passed through steel expanded line of Ateliers Roche (France), which is designed to produce grids of various sizes without the use of the emulsion. This eliminates the additional step of cleaning and reducing corrosion of the plates, which positively affects the battery life. Manufacturer of pasta is by mixing lead powder with demineralized water, electrolyte and special additives to mix your music without limits line paste Sanhuan (China).

Photograph 7 — steel Expanded line of Ateliers Roche (France)

Ready battery paste is supplied to the line pastanesi Accurate Product Moojin and Frimax (Denmark, South Korea and Spain, respectively) where the molten metal is pressed into the grid and sealed special battery paper. A continuous ribbon of double plates passes through a divider, after which the divided plate passing through a drying tunnel fall on the stacker and stack. Next, the robot places the stack of plates on a special pallet.

Photo 8 — stacker and robot stacker plates line pastanesi

To dry (drying) plates are kept in the cells of ripening and drying Sanhuan (China), where it is constantly supports the given parameters of temperature and humidity.

Photo 9 — Chamber of ripening and drying (Sanhuan (China))

Further, the battery plates are fed into the Assembly line onpiracy LaPneumatica (Italy) and AccurateProduct/Moojin (Denmark/South Korea). Here the plates are collected in groups, are connected in blocks and inserted in a plastic monoblock. After connection of all blocks in the chain, the cover is welded and soldered output (pole). At all stages of quality control.

Photo 10 — Line Assembly operations (LaPneumatica (Italy))

With the Assembly line semi-finished battery fall into the machine fill with electrolyte O. M. I.(Italy), and from there the batteries are loaded into large baths with water cooling Sovema (Italy), O. M. I.(Italy), form a chain and pass the process of formation of the charge.

Photo 11 — the Machine fill with electrolyte (O. M. I.(Italy))

After charging the batteries arriving on a line of finishing operations LaPneumatica (Italy), where the adjustment of the level of the electrolyte, washing, drying and installation labels are also monitored electrical characteristics. After completion of the entire production process, batteries are sent to the warehouse and after the point of sale.

Photo 12 — Line finishing operations (LaPneumatica (Italy))

It should be noted that the use of modern high-quality equipment and application of water treatment plants with a high degree of purification of air and industrial wastewater, allows to make production of storage batteries in the Republic of Belarus the most safe for the environment. Project battery plant IPower LLC allows to provide reduction of lead emissions to the atmosphere 40 times, compared with perhaps acceptable for a given production rule.

Photo 13 - Section 2-stage cleaning technology of filter mill to manufacture lead oxide (filter class HEPA 13)

On IPower LLC assembled a unique team of specialists and engineers having experience in major international companies (EXIDE), on battery plants in Ukraine, Bulgaria, Poland. Development and training of new employees taken to work in the shops, was carried out including with the support of foreign experts. Representatives of manufacturers of equipment came on production in Belarus, to train personnel in the intricacies of the installed equipment.

Photo 14 - Training representative of the manufacturer, equipment Accurate Product (Denmark)