Lithium-Ion Battery Recycling Line 1–2 t/h URSTAG

A 1 to 2 t/h lithium-ion battery recycling line is the balance point between a laboratory pilot line and a maximum-scale recycling factory: enough capacity for a solid collection contract, with a proportional investment and a reasonable installation footprint. At a throughput of 1 to 2 tons per hour, the line efficiently processes used batteries from electric vehicles, power tools and energy storage equipment.

A 1 to 2 t/h lithium-ion battery recycling line with shredding under N₂, pyrolysis and multi-stage dry separation is ready for continuous production and delivers black mass, copper and aluminum to specification. It is the choice of operators who have outgrown the capacity of compact equipment and want to move to structured production. See the full range of recycling equipment and the complete solutions.

Key Advantages for Processing Lithium Batteries at 1 Ton per Hour

• 1 to 2 t/h throughput, processes 8 to 16 tons per 8-hour shift, a volume sufficient for a mid-level collection contract.

• N₂ shredding at medium capacity, the shredder sized for 1 to 2 t/h under nitrogen ensures process safety at significant throughputs.

• Pyrolysis for clean black mass, the thermal treatment removes PVDF and electrolytes, producing clean calcined material for efficient separation.

• Three sellable products, black mass, copper granules and aluminum granules, with documentable quality per batch.

• PLC with continuous monitoring, all key parameters monitored and recorded; data available for quality certificates per batch.

• Complete gas treatment, secondary combustion, scrubber, activated carbon, catalytic combustion at the gas flow produced by 1 to 2 t/h of batteries.

• Documented environmental compliance, emissions treated to European standards, documentation available for permits.

• Scalable to higher capacity, additional shredding or pyrolysis modules are added as volume grows.

Technical Specifications, 1 to 2 t/h Lithium-Ion Battery Recycling Line

Applications and Context for a Medium-Throughput Battery Recycling Plant

A 1 to 2 t/h lithium-ion battery recycling line is sized for operators with regular collection contracts with electric vehicle manufacturers, importers of electronic equipment or energy storage network operators. At 1 to 2 tons per hour, the line can process several tens of tons per day, a volume sufficient to justify the investment in complete pyrolysis and gas treatment compared to a smaller unit.

The European regulation on batteries sets clear collection and recycling obligations; a 1 to 2 t/h lithium-ion battery recycling line delivered in Europe is designed in accordance with the requirements of Regulation (EU) 2023/1542 on batteries. For complete integration, see also the complete industry solutions.

At a throughput of 1 to 2 t/h, economies of scale start to become favorable: the processing cost per kilogram of battery drops compared to smaller equipment, and black mass supply contracts with refineries become easier to negotiate at significant regular volumes. The line brings you into the zone where you are a volume supplier, not an occasional one.

The gas treatment sized for 1 to 2 t/h of batteries per hour is more demanding than for smaller lines: the gas flow from pyrolysis and shredding is proportional to the volume of batteries processed. A complete gas treatment system (combustion chamber, scrubber, activated carbon, catalytic combustion) ensures that emissions remain within the limits of the European standards even at maximum capacity, a mandatory element for permitting.

The black mass produced has the same type of buyers as that of large industrial lines: hydrometallurgical refineries in Europe seeking local feedstock for extracting lithium, nickel and cobalt. At regular volumes of a few hundred tons per month, the operator can negotiate medium-term contracts with more stable prices than occasional spot sales.

The continuous recording of the pyrolysis and separation parameters by the PLC system allows the issuing of analysis certificates per batch: black mass composition, metal content and purity grades for copper and aluminum. This per-batch documentation is what premium refineries and producers of new cathode materials increasingly require.

Batteries Processable at 1 to 2 t/h

The line is configured for the main formats of used lithium-ion batteries. EV packs require a preliminary dismantling station; individual cells enter the shredder directly.

How It Works

1. The discharged batteries enter the feed conveyor sized for the rated throughput.

2. The N₂ shredder reduces them to pieces of 2 to 3 cm; the throughput is kept constant by the PLC.

3. The pyrolysis furnace calcines the material at a controlled thermal profile; the gases are treated in the complete sequence.

4. The zigzag separator, the magnetic separator and the rotary sieving separate the main fractions.

5. The crusher and the electrostatic separator finalize the separation of black mass, copper and aluminum.

6. The PLC records all parameters; the operator monitors remotely and intervenes on alarms.

A correctly tuned line keeps the product quality constant at rated capacity, batch after batch. Planned preventive maintenance based on PLC data minimizes unplanned stops.

Frequently Asked Questions

What does 1 to 2 t/h capacity mean in practice?

At 1 t/h and 16 hours of operation per day, the line processes 16 tons of used lithium-ion batteries daily, the equivalent of a few hundred electric vehicle packs or a few thousand kilograms of cylindrical batteries. At 2 t/h, the throughput doubles. The actual capacity depends on the format and weight of the batteries processed.

How is the black mass quality documented per batch?

The PLC system records the pyrolysis parameters for each batch. Black mass samples are taken periodically for composition analysis. The continuous PLC recording allows the issuing of analysis certificates per batch, required by the premium refineries that buy black mass.

What emissions do 1 to 2 t/h of batteries produce during pyrolysis?

At throughputs of 1 to 2 t/h, the gas treatment system must be sized for the corresponding gas flow: a combustion chamber with adequate capacity, an alkaline scrubber, activated-carbon filters and catalytic combustion. The complete treatment system ensures compliance with the European emission standards at maximum capacity.

Can it be expanded to higher capacity?

Yes. The line is modular: you can add a parallel shredder, an additional furnace or an EV pack dismantling system. The new modules are sized to work with the existing line, doubling or tripling capacity without replacing the base investment.

Why URSTAG?

URSTAG is a premium brand of recycling equipment, with over 15 years of experience. You don't just get a machine, you get a solution engineered by specialists, built from top-tier components and backed by a team that supports you from design through commissioning.

• European engineering, every machine and every complete line is designed by our engineering teams in Europe, with a focus on reliability, safety and energy efficiency.

• Premium components, we build on motors and automation from industry leaders: Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli.

• Over 15 years of experience, we know how materials and machines behave in real-world operation, and we configure each solution for your flow and volume.

• New equipment, configured for you, we supply new units, made to order for your application, with complete technical documentation.

• Delivery, installation and training included, we handle transport, commissioning and operator training, with support throughout the equipment's life.

As a premium brand, URSTAG relies on European engineering, top-tier components and experience. You choose a partner that supports your production long term, with equipment built to run reliably in demanding industrial environments.