Used lithium batteries contain black mass with lithium, nickel, cobalt and manganese, plus copper and aluminum foil, a valuable source of critical metals with rapidly growing demand. A lithium battery recycling plant with nitrogen protection, pyrolysis and dry mechanical separation turns these used batteries into three separate products: high-purity black mass, copper granules and aluminum granules.
A modern lithium battery recycling plant also addresses the main risk of processing used batteries: the danger of fire and explosion. Shredding under a nitrogen atmosphere removes oxygen from the work zone, neutralizing the ignition risk from residual electrolytes. See the full range of recycling equipment and where each one fits into the flow.
Key Advantages of a Lithium Battery Recycling Plant
• Nitrogen protection during shredding, N₂ inerting neutralizes the fire and explosion risk from residual electrolytes and cells with an internal short circuit.
• Pyrolysis for electrolyte removal, the pyrolysis furnace evaporates the electrolytes, calcines the material and removes the separator, preparing the fractions for dry separation.
• Three high-value products, black mass (Li, Ni, Co, Mn), copper granules and aluminum granules, each with its own market.
• Treated process gases, the pyrolysis gases pass through a secondary combustion chamber and a scrubbing system (scrubber + activated carbon + catalytic combustion) before discharge.
• Efficient dry separation, an air zigzag separator, magnetic separator, rotary sieving and electrostatic separator split the fractions without wastewater.
• Integrated PLC control, all stages coordinated from a single system, with continuous monitoring and an alarm on anomalies.
• Processes diverse formats, pouch, cylindrical and prismatic batteries and phone batteries, with procedures adapted to each type.
• Environmental compliance, the treatment of pyrolysis gases and dust capture ensure compliance with the emission standards in force.
Technical Specifications, Lithium Battery Recycling Plant
| Parameter | Value |
|---|---|
| Process type | Thermal + dry mechanical with nitrogen protection |
| Feedstock | Used lithium batteries: pouch, cylindrical, prismatic, phone |
| Stage 1 | Single-shaft shredder under a nitrogen atmosphere (N₂) |
| Stage 2 | Pyrolysis furnace: electrolyte evaporation, calcination, separator removal |
| Stage 3 | Air zigzag separator, magnetic separator, rotary sieving |
| Stage 4 | Crusher + sieving + electrokinetic separator for fine black mass |
| Products | Black mass (LiCoO₂/NMC/LFP), copper granules, aluminum granules |
| Gas treatment | Secondary combustion chamber + scrubber + activated carbon + catalytic combustion |
| Control | PLC, continuous flow, monitoring and alarm |
Applications and Context for Recycling Used Lithium Batteries
A lithium battery recycling plant addresses operators who collect and process used batteries from electric vehicles, energy storage, portable electronics and industrial sources. Demand for the metals in black mass, lithium, nickel, cobalt and manganese, is in structural growth, driven by the expansion of electric vehicles and energy storage systems.
At the European level, lithium-ion battery recycling is regulated and mandatory, with rising recovery targets; a lithium battery recycling plant delivered in Europe is designed in accordance with the requirements of Regulation (EU) 2023/1542 on batteries. For integration into a complete flow, see also the complete industry solutions.
The recovered black mass is the feedstock for the hydrometallurgical processes that extract lithium, nickel, cobalt and manganese. The purity of the black mass determines the yield of the hydro process and the price paid by buyers. A plant with pyrolysis and multi-stage dry separation produces black mass with documentable purity, a commercial advantage.
The separated copper and aluminum granules are additional products with their own market. The copper foil from the anode and the aluminum foil from the cathode are found in the final granules after the crusher and separation; these are sold to non-ferrous metal smelters. The three simultaneous revenue streams, black mass, copper and aluminum, make the plant economically viable even with fluctuations in metal prices.
Gas treatment is a non-negotiable element of any serious plant. The gases resulting from electrolyte pyrolysis contain volatile organic and acidic compounds, which must be neutralized before discharge. The secondary combustion chamber, the alkaline-solution scrubber, the activated-carbon filters and the catalytic combustion system complete the gas path.
Nitrogen protection at the shredding stage is the established solution for eliminating the fire risk of used lithium batteries. Batteries with a residual state of charge or with internal defects can generate heat and flammable gases at the first mechanical breach; inerting the work zone with nitrogen removes the oxidizer and makes the process safe at an industrial level.
Processable Battery Formats
An industrial lithium battery recycling plant is configured for several formats. The pyrolysis and separation parameters adapt to the battery chemistry and the cell format.
| Battery format | Notes |
|---|---|
| Pouch batteries (LiPo) | Portable electronics, drones, electric vehicles |
| Cylindrical batteries (18650, 21700) | Electric vehicles, power tools |
| Prismatic batteries | Electric vehicles, stationary energy storage |
| Phone and tablet batteries | Consumer electrical waste |
How It Works
1. The discharged used batteries are fed onto the input conveyor and enter the single-shaft shredder under a nitrogen atmosphere, which reduces them to pieces of 2 to 3 cm.
2. The material passes into the pyrolysis furnace, which evaporates the electrolytes, calcines the material and removes the separator; the gases are directed to treatment.
3. The air zigzag separator separates the casings and light materials from the heavy fractions (anode + cathode).
4. The magnetic separator recovers the steel casings from the mix of casings.
5. The rotary sieving sieves out the raw black mass; the material above the sieve goes to the crusher for further release of black mass.
6. The crusher breaks the anode-cathode pieces, the cyclone collects the fine black mass, and the electrostatic separator separates the final copper and aluminum granules.
The PLC system coordinates all stages, monitors the furnace temperature, the nitrogen pressure and the treatment gas flow, and signals any parameter outside the limits. A correctly sized and operated plant produces black mass, copper and aluminum at constant quality.
Frequently Asked Questions
Why is nitrogen protection needed during shredding?
Used lithium batteries may contain a residual state of charge or internal defects that generate heat and flammable gases at the first mechanical breach. Nitrogen removes oxygen from the work zone, neutralizing the fire and explosion risk. Without N₂ inerting, the process does not meet safety standards.
What is black mass and what is it used for?
Black mass is the black powder resulting from the active materials of the battery electrodes, containing lithium, nickel, cobalt, manganese or iron phosphate. It is the feedstock for the hydrometallurgical processes that extract and refine critical battery metals.
What battery chemistries can the plant process?
A correctly configured plant processes batteries with NMC, NCA, LFP and LiCoO₂ chemistries, adapting the pyrolysis temperature and the separation parameters for each type.
How are the pyrolysis gases treated?
The gases pass sequentially through a secondary combustion chamber at high temperatures, an alkaline-solution scrubber, activated-carbon filters and a catalytic combustion system. This sequence removes volatile organic compounds, acids and fine particles, ensuring emission compliance.
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.
