Elkem Solar - Raw Material System

The Client

 

Elkem Solar is a leading manufacturer of high-quality materials for solar panels. The company focuses on developing innovative solutions for renewable energy production, with particular expertise in silicon-based components essential to photovoltaic technology.

The Challenge

 

Elkem Solar required a sophisticated material handling system that could meet several critical demands:

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• Precisely transport and mix silicone and calcium in specific proportions

• Deliver these materials consistently to a furnace operating at exceptionally high temperatures

• Maintain absolute accuracy in the mixture ratios to ensure product quality

• Design a system capable of withstanding the extreme thermal conditions near the furnace

• Create a fully automated solution requiring minimal operator intervention

• Integrate comprehensive control systems for precise monitoring and adjustment

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How do you design a conveying system that maintains precision when handling materials destined for extreme temperatures? This was the fundamental question our team needed to address.

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The Solution

 

Central Conveyors engineered a bespoke automated conveying system specifically designed to meet Elkem Solar’s exacting requirements. Our comprehensive solution features:

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• Four custom-designed stainless steel silos – two dedicated to calcium storage and two for silicon

• Precision-engineered belt conveyors equipped with highly accurate weighing scales

• Automated valve systems that regulate material discharge based on predetermined weight parameters

• Integrated 24-volt signalling system that triggers valve closure once target weights are achieved

• Bucket elevator technology achieving vertical elevation of 10 metres

• Specialised belt-mounted buckets for efficient material transfer

• Troughed vibratory conveyors that facilitate material movement through oscillation

• Heat-resistant components capable of withstanding furnace-proximity temperatures

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The materials journey through our system is both elegant and precise. Starting from the scaled flat belt conveyor, materials travel to the bucket elevator, which elevates them by 10 metres. Traditional belt conveyors wouldn’t suffice at the furnace interface – the extreme temperatures demanded an innovative approach. By implementing troughed vibratory conveyors, we created a solution that balances efficiency with thermal resilience.

 

Adding insulation to critical components helps keep the system functioning optimally even under challenging thermal conditions.

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The Control System

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Our expertise extended beyond mechanical design to comprehensive control integration:

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• Fully engineered control system incorporating Siemens hardware and PLCs

• Complete system management from initial dispensing to final delivery

• Design, manufacture, and programming handled by Central Controls Ltd (a division of the Central group)

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This integrated approach allowed us to deliver a complete turnkey solution, with every aspect of the system working in harmony to achieve Elkem Solar’s objectives.

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The Results

 

The implemented conveying system has revolutionised Elkem Solar’s material handling process by providing:

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• Exceptional accuracy in material mixing, ensuring consistent product quality

• Reliable performance even in the challenging high-temperature environment

• Fully automated operation that minimises labour requirements and human error

• Seamless integration with existing manufacturing processes

• Improved production efficiency and reduced material waste

• Enhanced safety by removing operators from proximity to extreme heat zones

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The system now plays a crucial role in Elkem Solar’s manufacturing process, contributing to the production of high-quality components for solar panels. This project demonstrates how innovative engineering can overcome extreme challenges while supporting the growth of renewable energy technologies.