Engineering Reference Case Profile · Battery Gigafactory ATEX Dust Collection

Battery Cathode Powder Dust Collection · Gigafactory ATEX IIIC

A composite reference case based on representative battery gigafactory cathode/anode dust collection deployments — supplying ATEX II 3D Ex tc T125°C IIIC certified plug fans + high-pressure CDU fans for cathode (NMC) powder handling with 3.2 kPa static for dense cartridge filter face, ramping to 80,000 fans/year across gigafactory build-out.

Project size: Gigafactory · cathode workshop · 12,000 ATEX plug + 5,000 high-pressure CDU per year Reference period: Composite reference · 2025–2026 deployment pattern Geography: Asia-Pacific battery gigafactory segment

About this case profile: This is an anonymized composite reference case based on representative LONGWELL platform deployments in the Industrial Dust · Battery Cathode Workshop segment. It illustrates the engineering challenge, solution architecture, and measurable outcomes typical of projects in this class. Performance numbers reflect LONGWELL platform validated specs plus industry-standard improvement deltas, not a specific named customer claim. Real customer references are available under NDA on project qualification (sales@longwellfans.com).

1 · Challenge

NMC cathode powder dust = combustible electrically-conductive (IIIC) — most aggressive ATEX dust group.
ATEX II 3D Ex tc T125°C IIIC required for collector interior fans (zone 21).
Modern dense cartridge filter media requires 1,500–3,000 Pa fan static pressure — exceeds standard plug fan envelope (1,800 Pa).
Gigafactory ramp: 12,000 ATEX plug fans + 5,000 high-pressure CDU fans per year, sustained through 2030.
OSHA NFPA 652 + EU CBAM-aligned emissions documentation per shipment.

2 · Solution Architecture

Per gigafactory cathode workshop: 12,000 LWBE3G-ATEX-IIIC in cartridge dust collectors (zone 21 interior). 5,000 LWHV-ATEX-450-HP on dense cartridge filter face for cathode dust capture at 3.2 kPa static. 3,000 LWAE3G-ATEX-630 for workspace clear-air ventilation. All units include IEC 60079-31 ATEX certificate per shipment + NFPA 652 compliance declaration.

Bill of materials

LONGWELL SKU	Type	Qty	Key spec
LWBE3G-ATEX-IIIC	ATEX EC plug fan	12,000 units/yr	Ø355–Ø560 mm, II 3D Ex tc T125°C IIIC, electrically grounded impeller + shaft per IEC 60079-31, 87% η peak
LWHV-ATEX-450-HP	ATEX high-pressure plug fan	5,000 units/yr	Ø450 mm, 3.2 kPa static, II 3D Ex tc T125°C IIIC, anti-static + spark-resistant housing
LWAE3G-ATEX-630	ATEX workspace ventilation axial	3,000 units/yr	Ø630 mm, ATEX II 3D Ex tc T125°C IIIC for cathode-workspace clear-air ventilation

3 · Modelled Outcomes — Typical Range

How to read these figures: the values below are modelled for this composite scenario — LONGWELL platform specifications combined with industry-standard deltas. They are a planning range, not measured results from one named project. Verified data from real deployments is in Section 6.

ATEX certification scope

II 3D Ex tc T125°C IIIC

full combustible-dust IIIC

Static pressure capability

3.2 kPa

LWHV-ATEX-450 max

Annual fan supply

20,000 units

ATEX + high-pressure + workspace

ATEX-related incidents (2-yr)

in field service

Lead time first batch

6 weeks

vs 16–22 wk European ATEX

CapEx delta vs ebm-papst RadiPac ATEX

−45%

at gigafactory volume

4 · Implementation Timeline

Week 0Gigafactory PO for 20,000-unit annual program

Week 1–5ATEX recertification + tooling for IIIC scope

Week 6First 1,500-unit batch ships

Month 3Series cadence at 1,700 units/month

Year 1Cumulative 20,000 fans deployed across cathode workshop

Year 2+Steady 1,700 units/month + commissioning at next gigafactory phase

5 · Engineering Lessons

ATEX dust group IIIC (combustible electrically-conductive) is more aggressive than IIIB (grain) or IIIA (sugar). Battery cathode dust requires full IIIC scope — IIIB-only certification is insufficient.
3.2 kPa static pressure capability (LWHV-ATEX vs standard plug at 1.8 kPa max) was the binding spec for modern dense cartridge filter face. Standard plug fans starve below design CFM in this duty.
ATEX certificate per shipment (not as one-time type test) is mandatory for permit-issuing authorities. Compliance statement attached per bill of lading.
Workspace clear-air ventilation (LWAE3G-ATEX-630) in zone 22 (occasional dust) is often forgotten in dust-collector OEM spec — but required for OSHA compliance at the workplace.
Sustained 1,700 fans/month cadence required dedicated ATEX production line at Yuyao + Hai Phong — competitor European brands cannot match this volume.

6 · Verified Project Evidence

Everything below is drawn from actual project correspondence and from photographs taken during production and shipment. Model numbers, duty points and test results are stated as they occurred. Customer names are withheld; no pricing is published.

Sweden — industrial dust and air-cleaning units, high static duty

EC backward-curved · delivered

Supplied: LWBE3G250-102NS-011 — 230 VAC (200–277 V / 176–264 V), 50/60 Hz, 4,100 rpm, 3.4 A, 750 W, up to 2,950–3,039 m³/h and 1,420–1,442 Pa, 93 dB(A), IP55, with 0–10 VDC / PWM / RS485 control.
Why this duty is different: a dust collector’s resistance rises as the filter loads. The fan is selected to hold output while pushing through a dirty HEPA or industrial cartridge, so the shape of the pressure curve at high speed matters more than the headline airflow.
A model-code decision that saved the customer a re-certification: the customer’s appliance is certified to EMC, LVD, SVHC, RoHS, REACH and CE, and the fan model number is written into those reports. Renaming LWBE3G250-102NS-011 to a new code would have forced re-testing of the whole machine, so the original designation was kept in production and on documents. Worth checking before any internal part-numbering cleanup.

Poland — dust-extraction equipment, transit-damage investigation

Failure analysis · batch verification · delivered

Model: LWBE3G190-072NS-011 — Ø190 mm wheel on a 72 mm motor, 230 V 50/60 Hz, 64 W ±16%, 0.53 A, 2,940 r/min ±10%, IP55, Class B, hipot 1,800 VAC for 1 s with trip current < 10 mA.
What happened: three suspect units were pulled back by courier and stripped down. The bearings had been damaged by heavy vibration and compression in transit — the outer cartons were intact, which is what makes this failure mode easy to miss.
How it was closed out: a full inspection report was issued for the same 1,000-piece shipment, with measured speed 3,200–3,232 r/min, measured power 65.9–67 W and hipot passed. Packaging was then redesigned to add shock absorption around the bearing seat.
The transferable lesson: on long overland routes an intact carton is not evidence of an undamaged fan. Cushioning has to be designed around the bearing, not around the box.

ETL Recognized Component label on LWBE3G190-72PS-03 showing UL 507 and CSA C22.2 No.113 — ETL Recognized Component marking on the Ø190 mm platform: AC 230 V, 170 W, 4,100 rpm, IP55, to UL STD.507 and CSA STD.C22.2 No.113, Intertek control number 5022563.

EC backward-curved plug fans with inlet cones in a partitioned wooden crate ready for shipment — Plug-fan modules in partitioned crating before dispatch. Individual cells stop the wheels from contacting each other in transit.

United States — fume-extraction equipment on a 120 V grid

Voltage-specific variants · delivered

Supplied as dedicated part numbers: LWBE3G225-092PU-14 backward-curved with mounting bracket, and LWFE3G180-102DU-03 forward-curved — both built for 120 V / 60 Hz rather than re-labelled 230 V stock.
Selection basis: the 230 V reference units (190 W, 1,545 m³/h, 731 Pa, 3,000 rpm; and 400 W, 2,000 m³/h, 720 Pa, 1,550 rpm) were used for initial duct sizing, then measured 115 V data was issued once the prototypes were tested.
Process point: a separate factory part number was created for the low-voltage variant (…-092PS-13 becomes …-092PU-14). Sharing a code between 230 V and 120 V builds is how the wrong motor ends up on a production line.

Export crates of EC centrifugal fans, strapped and stretch-wrapped on pallets with LONGWELL shipping labels — EC centrifugal fans crated for export on the dust-collection programme — plywood cases with corner brackets, strapping and stretch wrap, each carrying a LONGWELL label with model, quantity and net/gross weight for the customer’s goods-in check.

The LONGWELL assembly line. Dust-collection customers audit the line before they qualify the fan, so this is usually part of the package rather than an afterthought. 5 s loop, no audio.

Fan performance figures are quoted from LONGWELL controlled datasheets and are tested per AMCA 210/211 methods; third-party reports available on request. EC versus AC energy saving is approximately 30%, higher under strongly varying load — confirm against your own load profile. Final selection must be confirmed against the actual duty point (airflow / static pressure / voltage / control method) and project validation.

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