This article presents a comprehensive case study of a nickel-metal hydride (NiMH) battery powder pneumatic conveying project implemented for a battery enterprise in Xinxiang, Henan Province. The project focuses on the safe and efficient transfer of positive and negative electrode powders using a nitrogen gas circulation system. This solution is specifically designed for the unique requirements of battery material handling, ensuring minimal contamination, zero oxidation, and high operational reliability. The entire system is engineered and supplied by Shandong Headpowder Engineering Co., Ltd., a leading provider of advanced powder conveying technologies based in China’s Shandong Province.
The client, a well-established battery manufacturer located in Xinxiang, Henan, specializes in the production of nickel-metal hydride batteries. Their production process involves the handling of fine, reactive powders used for both positive and negative electrodes. These powders are highly sensitive to moisture, oxygen, and mechanical degradation. Traditional mechanical conveying methods, such as screw conveyors or belt conveyors, pose risks of powder contamination, dust explosion, and material degradation. The client required a closed-loop, inert gas-based conveying system that could maintain the purity and chemical stability of the battery materials throughout the entire transfer process. The primary challenges included eliminating oxygen exposure, preventing static electricity buildup, and ensuring continuous, dust-free operation. Nitrogen gas circulation was identified as the optimal solution because nitrogen is an inert gas that displaces oxygen and moisture, thereby preserving the integrity of the nickel-metal hydride battery powders.
At the heart of this project is the nickel-metal hydride battery powder conveying system, which is designed to transport both positive electrode powder (typically nickel hydroxide or nickel oxide) and negative electrode powder (typically hydrogen storage alloys) from storage silos to mixing and coating stations. The system utilizes dense-phase pneumatic conveying powered by compressed nitrogen gas. This method minimizes particle breakage and abrasion, which is critical for maintaining the electrochemical performance of the battery materials. The entire conveying line is constructed from stainless steel with smooth interior surfaces to prevent powder adhesion and cross-contamination. Special attention is given to the design of the feed hoppers, rotary valves, and discharge points to ensure a consistent, controlled flow rate. The system is fully automated, with PLC-based controls that monitor gas pressure, flow rate, and material level in real time. This ensures that the battery material conveying process is both efficient and repeatable, meeting the strict quality standards required for high-performance NiMH batteries.
The battery material conveying system integrates a dedicated nitrogen gas circulation loop, which is a key feature of this project. Instead of using compressed air, which contains oxygen and moisture, the system uses high-purity nitrogen as the conveying medium. The nitrogen is recirculated through a closed loop, passing through filters, dryers, and pressure regulators before being reused. This approach significantly reduces nitrogen consumption, lowers operating costs, and ensures a consistent inert atmosphere. The nitrogen gas circulation system is equipped with oxygen sensors that continuously monitor the oxygen level within the pipeline. If the oxygen content exceeds a preset threshold, the system automatically purges the line with fresh nitrogen and triggers an alarm. This safety feature is essential for handling flammable or reactive battery materials. The circulation loop also includes a heat exchanger to control the temperature of the nitrogen, preventing thermal degradation of the powder. By combining nitrogen gas circulation with pneumatic conveying, the system delivers a safe, clean, and highly reliable solution for battery material transfer.
Several key advantages make this nitrogen circulation pneumatic conveying system the preferred choice for nickel-metal hydride battery powder handling. First, the inert atmosphere completely eliminates the risk of oxidation, which is a common cause of capacity loss in NiMH batteries. Second, the closed-loop design prevents dust emission into the workshop environment, improving worker safety and meeting stringent environmental regulations. Third, the dense-phase conveying mode reduces the velocity of the powder, minimizing wear on the pipeline and reducing the generation of fine dust. Fourth, the system is highly scalable and can be easily integrated with existing production lines. Fifth, the use of nitrogen gas circulation reduces the overall cost of consumables, as the nitrogen is continuously recycled and only a small amount is lost through leakage or purging. These benefits directly contribute to higher product quality, lower maintenance costs, and improved operational efficiency for the battery manufacturer.
The project was executed in phases, starting with a detailed site survey and process design by the engineering team of Shandong Headpowder Engineering Co., Ltd. The existing layout of the factory in Xinxiang was carefully analyzed to determine the optimal routing of the conveying pipelines. A customized nitrogen gas circulation unit was designed and fabricated, including a nitrogen generator, compressor, filtration system, and control panel. The entire system was installed and commissioned within the agreed timeline. Post-installation testing demonstrated a conveying capacity of up to 2 tons per hour for positive electrode powder and 1.5 tons per hour for negative electrode powder, with a conveying distance of 50 meters. The oxygen level in the conveying line was maintained below 0.5%, well within the safety and quality requirements. The client reported a significant reduction in material waste and a noticeable improvement in the consistency of the final battery electrode slurry. The system has been in continuous operation for over 12 months with zero unplanned downtime, confirming its reliability and robustness.
Shandong Headpowder Engineering Co., Ltd. (company abbreviation: headpowder) is a professional engineering company headquartered in Shandong, China. The company specializes in the design, manufacturing, and installation of pneumatic conveying systems, powder processing equipment, and gas circulation solutions. With years of experience in the battery materials industry, headpowder has developed a deep understanding of the unique challenges associated with handling fine, reactive, and abrasive powders. The company’s engineering team provides end-to-end project support, from conceptual design and feasibility studies to detailed engineering, equipment supply, installation, and commissioning. headpowder is committed to delivering high-quality, cost-effective solutions that meet the specific needs of each client. The success of the Xinxiang nickel-metal hydride battery powder project is a testament to the company’s technical expertise and customer-centric approach.
For more information about this project or to discuss your own battery material conveying requirements, please contact the headpowder team. The project manager, Mr. Zhang, is available to provide detailed technical consultation and project references. You can reach Mr. Zhang directly via WeChat at 15662777102. Whether you need a nitrogen gas circulation system, a complete pneumatic conveying line, or a customized solution for battery material handling, headpowder is ready to assist. Please note that for any inquiries, it is best to use WeChat as the primary communication method, as specified by the company. The team at Shandong Headpowder Engineering Co., Ltd. looks forward to collaborating with you on your next powder conveying project.
Shandong Headpowder Engineering Co., Ltd.
156-6277-7102（Zhang manager） 
0531-83386006 
Jinan City, Shandong, China Province 
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