What Is The Process Of Scrapping Lithium Batteries?

With the rapid development of the new energy vehicle industry, the first batches of lithium batteries are gradually reaching the end of their operational lifecycle. How to efficiently, safely, and environmentally responsibly process and recycle end-of-life lithium batteries, achieving resource recycling and environmental protection, has become a critical issue for the industry’s sustainable development. The recycling process for discarded lithium batteries is complex and meticulous, encompassing key stages such as collection, sorting, dismantling, discharging, crushing, separation, and extraction. Each step is critical, directly impacting not only resource recycling but also environmental protection and sustainable development. The following provides a detailed overview of effective recycling and processing for end-of-life lithium batteries.

Sources and Collection of End-of-Life Lithium Batteries

End-of-life lithium batteries primarily originate from battery manufacturers, electric vehicles, energy storage facilities, 3C digital products, and the general consumer market. Digital product waste lithium batteries are predominantly found in computers, mobile phones, discarded electronics, power tools, and household appliances. This battery type exhibits scattered distribution and diverse models, necessitating dedicated recycling channels for collection. Battery manufacturers generate scrap materials and defective products during lithium battery production. These raw materials are relatively concentrated, facilitating easier recovery and separation. Scrap and defective products account for up to 30% of battery production output. Consequently, it represents a significant source for raw material recovery. Presently, with the rapid surge in new energy vehicles, power battery production has substantially increased, becoming the primary focus for lithium battery recycling. Energy storage batteries, meanwhile, require sourcing from base stations, signal towers, equipment rooms, and discarded shared power banks.

Sources and Collection of End-of-Life Lithium Batteries

Sources and Classification of Waste Batteries

After collection, discarded lithium batteries require sorting. Classification is primarily based on battery type, appearance, capacity, composition, and application. Based on lithium’s physical state, they can be categorised as: lithium metal batteries and lithium-ion batteries. By charge/discharge cycles, they are divided into: disposable lithium batteries and rechargeable lithium batteries. By appearance: cylindrical lithium batteries, prismatic, aluminium casing, pouch, plastic casing, etc. By electrode material: lithium iron phosphate batteries, ternary lithium batteries, lithium cobalt oxide batteries, etc. Different processing techniques are required for recycling various lithium battery types. Consequently, the initial sorting stage is paramount. Precise classification facilitates optimisation of subsequent recycling processes, thereby enhancing recovery efficiency.

Sources and Classification of Waste Batteries

Lithium Battery Recycling Production Line

Disassembly constitutes the critical phase in waste lithium battery recycling. Pre-discharge treatment is essential to prevent short circuits and explosions during dismantling. Common discharge methods include: saltwater discharge, puncture discharge, and resistive discharge. For automotive battery packs, disassembly must first be performed to separate them into individual lithium battery cells. After discharging, the spent lithium batteries undergo physical mechanical crushing to facilitate subsequent recycling. Key equipment in lithium battery recycling machinery includes crushers, fine screening units, and gravity separators. The entire production line processes spent lithium batteries through crushing, pulverising, fine grinding, screening, gravity separation, and de-powdering. The waste lithium batteries are sorted into: Black Mass, copper granules, aluminium granules, and plastic. Magnetic separators isolate iron from the crushed battery materials. Air classification separates plastic separators from the battery materials. Dust generated throughout the process is managed via cooling, dust removal, spraying, mist separation, adsorption filtration, and high-altitude emission procedures. This facilitates compliant exhaust gas discharge.

lithium battery recycling machine

Material Regeneration and Hydrometallurgical Extraction

Following hydrometallurgical extraction of Black Mass, the recovered metallic elements and organic compounds undergo further processing to achieve material regeneration. Key metals in lithium batteries include lithium, cobalt, nickel, copper, and aluminium, all possessing significant recycling value. These elements are refined through high-temperature smelting and hydrometallurgical extraction to produce high-purity metal products. Extracted metals may be reused in new battery material production or other industrial applications. Organic compounds undergo high-temperature decomposition into gaseous, solid, or liquid forms, ensuring complete breakdown of hazardous substances. Metals are isolated through hydrometallurgical separation.

In summary, the recycling of waste lithium batteries is a complex and meticulous process. It necessitates the integrated consideration of multiple stages and technologies. Through the synergistic operation of collection, sorting, dismantling, recovery, chemical processing, and material regeneration, lithium battery recycling machine can achieve the effective processing of waste lithium batteries and the circular utilisation of resources. Concurrently, it is essential to strengthen research and innovation into novel recycling technologies for waste lithium batteries. This will drive the standardisation and scaled development of the industry, contributing to environmental protection and sustainable development.

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