Overview of UHMWPE Separator Production Project

Ultra high molecular weight polyethylene separator (hereinafter referred to as the PE separator) is a kind of micro porous membrane that uses polyethylene as base material and silica as filler material. It is mainly used for lead-acid batteries to separate positive and negative plates, widely used in the energy storage industry. The lead-acid battery PE separator production line with mature technology and processes can effectively control the investment risk of UHMWPE separator manufacturers and obtain higher project returns.

Equipment composition of PE separator production line

1) Raw material storage, mixing section. First design the machine according to the characteristics of raw materials, including structure of silo, heating system, convery method, control logic, etc. When Mixing raw materials, not only focus on the uniform dispersion of raw materials, but also to avoid the leakage of dust.

2) Extrusion and calendering section. In order to ensure good plasticizing and dispersion, we should design screw extruder with special screw elements according to the material characteristics. And, the channel of the die, the structure of the calender, are specially designed according to the material characteristics.

3) Extraction and pore forming section. This machine is designed according to process requirements , the market may don’t have this machine. This machine is directly related to the porosity and oil content of PE separator, there are many technical know-how. For example: how to stabilize the control of oil content, how to avoid the break and folds of storage battery separator, how to control the tension, etc. In addition, the sealing of system, anti-corrosion, drying process control also need special design.

4) Treatment of wetting agent coating section. This machine is used to hydrophilic treatment on PE separator, this part includes the wetting agent dilution, coating, drying, etc. The difficulty is how to control the uniformity of wetting agent and the amount of coating, which requires special mechanical structure to achieve.

5) Defect detection and winder section. Pinhole detector can online detect pin holes and other defects in PE separator, and make the corresponding mark and record. The tension control and web guider is very important in this section, directly affect the appearance of the finished product and subsequent processing. The winder includes special tension control and web guider, the software has special algorithm.

6）Liquid raw material recycling section. This section of the machine is directly related to the cost of PE separator and environmental issues. Many PE separator manufacturers often ignore this section. If this section is not perfect, even if it can make a qualified product, the cost will be high and lose competitiveness, and will cause harm to the working environment and the surrounding environment.

The method of UHMWPE project construction

The storage battery PE separator project construction can be used in two different ways: a) The project construction contract to professional manufacturer of complete PE separator production line. b) In accordance with the technical requirements, storage battery separator factories buy equipment and organize installation. The first way, can better ensure the successful construction of the production line, to ensure smooth operation, but the total package manufacturers will charge extra fee, the investment will increase. Second ways to save part of the cost, but the construction risk is relatively large, the need for users to have more professional team organization installation and debugging.

Besides, this project is a systematic project which needs an overall planning. The whole process needs to be designed according to the users’ PE separator products. The structure and layout of the equipment can also be adjusted according to the user’s requirements. The project requires a comprehensive consideration of raw materials storage, equipment layout, operating space, etc., in order to optimize the entire process of materials and ensure the safety of the production process. The project is not only to establish the production line, but also the design of the production process, and after the completion of the test, to determine the various process parameters, control parameters, etc. The company needs to establish a complete product and semi product quality control system, including the testing room of the physical and chemical equipment and the detection methods and standards. In order to ensure smooth production and good product quality, technical training is very important.

Workshop, utility and staffing requirements

Calculating according to a annual production capacity of 5 million square meters production line(back web thickness 0.25mm products). Installation of the main line requires plant with a length of not less than 60 meters, width of not less than 24 meters, a height of not less than 8 meters of space, in which height of the raw material mixing part not less than 12 meters. Project construction cost includes workshop, public facilities, production line equipment, installation materials and labor costs, technical support, etc. Plant and utility costs vary according to different plant structures, different configurations, and different regions. In terms of staff configuration, If in accordance with a production line, each team work 8 hours, 24 hours a day without stopping, need to be equipped with 4 teams of staff to ensure the smooth operation of the entire storage battery PE separator production line.