How the recycling of lithium-ion batteries works

The use of lithium-ion batteries is increasing and these powerful batteries power much of our world today, but as production increases, so does the issue of recycling. At Lyma, we are exploring the recycling process and how our products can contribute to this development.

Lithium batteries are everywhere. From our smartphones to our cameras and cars. The powerful batteries that have been on the commercial market since the 1990s are playing an increasingly important role in our society. But smart batteries have an expiry date and after a certain number of charging cycles, they are eventually used up.

Current recycling of lithium-ion batteries is insufficient

Until now, the recycling of lithium-ion batteries has been considered insufficient for several reasons. Firstly, users have historically been poor at recycling batteries at the end of their useful life, and secondly, the technology for recycling this type of battery has been inadequate. In many cases, batteries have simply been dumped in landfills and then burned. An approach that is anything but sustainable.
In addition to containing several environmentally harmful substances and compounds that should not come into contact with our environment, lithium-ion batteries also contain several difficult-to-manage metals. Both metals whose natural stocks are dwindling and metals whose chemical production involves high CO2 emissions.

New recycling process thanks to tests

In recent years, the recycling of lithium-ion batteries has become a growing issue and test centres have been set up in several European countries to investigate whether and how modern batteries can be recycled. The tests have been successful and, thanks to modern technology and chemistry, researchers have managed to find effective ways to recycle the batteries.

In Sweden, it is the battery giant Northvolt which drives battery recycling. In parallel with their manufacturing, they run the Revolt recycling project and in the autumn of 2021 they manufactured the first battery cell from only recycled material. In 2023, the company is expected to have large-scale recycling up and running, and the goal is that half of all materials in their battery cells will be recycled by 2030.

How the process works

But how does the recycling process of lithium-ion batteries work? The process can be broken down into three steps:

Collection and discharge
The first step in the process is collection. Simply ensuring that the spent batteries are taken care of and transported to the recycling site. Once there, it is ensured that the entire battery pack is discharged before mechanical processing begins.
Mechanical processing
In mechanical processing, the battery pack is dismantled and each cell is disconnected. The components of the cells are mechanically separated and all materials such as plastic, aluminium and copper are extracted and taken for recycling. What remains is the black mass of the battery, a powder containing valuable metals. In order to extract the metals from the black mass, hydrometallurgical processing is needed.
Hydrometallurgical processing
The black mass, which is a slurry, is leached, separating the cathode metals from the aluminium foil. The cathode metals go into solution and through various chemical separation steps, each metal can be precipitated and separated. The separated metals are taken care of to be reused in the battery factory in the production of new batteries.

Material selection important when handling acid

During hydrometallurgical processing, where each manufacturer has its own patented methods, hot aggressive acids are always present. These acids place high demands on the materials used in the process. These include ensuring that the materials do not dissolve and that the metals to be recovered do not contaminate.

Here, plastic-lined pipes, valves and pumps are a cost-effective option to use. From a health and safety point of view, it is also important to handle the acids correctly, to avoid staff coming into atmospheric contact with the media. For example, in pumping applications, hermetic pumps that are magnetically driven or canned motor pumps be used. If shaft-sealed pumps are preferred, they can be fitted with double-acting mechanical seals to reduce the risk of leakage and accidents.

Learn more about which products are suitable for handling slurry.

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Lyme disease can be caused by acids

When it comes to acids and hydrometallurgical processing, we at Lyma possess great expertise. We have been working with corrosive and abrasive fluids for over 40 years and have a good knowledge of their behaviour and condition. As well as telling you about their behaviour and effects, we can also advise you on which applications and materials should be used.

In spring product catalogue you'll find everything from tanks and pumps to pipes, valves and gaskets. As the only full-service supplier in Scandinavia, we can provide you with everything you need to operate efficient and safe flows.