In today's industrial landscape, handling hazardous substances with utmost care is critical. We spoke to Manuel Dittrich, Director of the Test Center for Bulk Material Handling at AZO, about our new, advanced solution facility, the Toxi-Container, designed to safely manage and analyze hazardous substances, including carcinogenic raw materials. In this article, we’ll explore the unique features we learned about the Toxi-Container from Manuel, highlighting its importance in ensuring the safety of both employees and the environment.
Advanced Design for Maximum Safety
The Toxi-Container is meticulously crafted with a laboratory of approximately 32m² and a room height of 2.7m. Entry into this specialized container is strictly regulated; personnel must wear a full-body protective suit equipped with a respirator mask and filter system. This protective gear is donned in a small anteroom, ensuring no contaminants are carried into the main area.
Efficient Air Filtration System
One of the standout features of the Toxi-Container is its air filtration system. This system replaces the entire air volume approximately 14 times per hour, ensuring a consistently safe and contaminant-free environment. The HEPA filter, with a filter class H14, is pivotal in maintaining this high level of air purity. Fresh air is supplied from the top at a height of 2.6m, and extraction occurs at 1m, creating a diagonal airflow that optimizes air exchange and contaminant removal.
Comprehensive Laboratory Capabilities
Within the Toxi-Container, a range of initial laboratory analyses can be performed. These include bulk density measurements, particle size distribution via vibrating sieve (sieve tower analysis), and residual moisture content determination. These analyses are crucial, particularly in industries such as Battery and Additive Manufacturing, where the quality and consistency of raw materials are non-negotiable.
Specialized Testing and Equipment
The Toxi-Container is equipped for a variety of specialized tests. Small series tests, such as dosing tests with small dosing units or sieving tests with a flat sieve machine using ultrasonic technology, can be conducted. This equipment, specifically designed for sieving metal powders for 3D printing, allows for sieving with mesh sizes of 63 and 100 µm. These sieving stations are housed within a GlooveBox, further enhancing safety.
Working with Nitrogen
For metal powders, avoiding moisture is critical. The Toxi-Container can operate with nitrogen, ensuring that no moisture infiltrates the metal powders. During tests, the setup is overlaid with dry nitrogen air in the GlooveBox, maintaining the integrity of the raw materials. Future plans include implementing pneumatic conveying within the Toxi-Container, also utilizing nitrogen overlay.
Strict Regulations and Safety Protocols
Handling and delivering hazardous substances to the Toxi-Container is governed by strict regulations. All deliveries must be pre-approved by the management of the test center. Hazardous substances are stored in a dedicated hazardous substance storage container, and all equipment is cleaned in specialized rooms, adhering to all safety regulations. This rigorous process ensures the safety of employees and the environment, despite the considerable extra work involved.
Focus on Additive Manufacturing
The Toxi-Container has primarily been used for screening tests within the Additive Manufacturing team. Innovations on screening machines are continually tested with various metal powders. The future integration of a pneumatic conveying system, with a diameter of DN19mm and a conveying distance of approximately 35m, is on the horizon. Additionally, testing of dosing devices such as the AZODOS® P30 or the AZO dosing screw DFS50 is planned.
Uncompromising Safety Standards
In line with our OEB Whitepaper, the Toxi-Container operates without a fixed limit value based on an OEB Level. Employees work with the highest level of personal protective equipment: protective overalls (PPE category III) type 5/6, double gloves, and the Dräger Explore 8000 respirator mask. This unwavering commitment to safety ensures that every operation within the Toxi-Container is conducted with the utmost care.
The Toxi-Container represents a significant advancement in the safe handling and analysis of hazardous substances. Its comprehensive design, advanced filtration system, and specialized testing capabilities make it an indispensable tool in industries requiring meticulous handling of dangerous materials. By prioritizing safety and efficiency, the Toxi-Container sets a new standard in hazardous substance management, safeguarding both employees and the environment.
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