Sorting and Segregation of Recyclable Materials from Battery Packs

Identify and classify recyclable materials from battery packs (metals, plastics, electrolytes).

Metals: Copper (foils, busbars), Aluminium (casing, tabs), Steel (module frames) • Plastics: Housings, separators, insulation • Black Mass: Cathode/anode powder (Li, Ni, Co, Mn, graphite) • Electrolytes & Solvents: Organic carbonates (flammable), LiPF₆ (toxic)

Apply mechanical and chemical separation techniques for material recovery.

Mechanical: Crushing & sieving (size-based separation), Magnetic separation (ferrous metals), Eddy current separation (non-ferrous metals) • Chemical: Leaching (acid/alkaline) for metal recovery, Solvent extraction for electrolyte removal

Operate sorting equipment (sensors, conveyors, shredders) to separate battery components

Near-infrared (NIR) sensors (plastic identification) • X-ray fluorescence (XRF) (metal composition analysis) • Air classifiers (light/heavy material separation)

Ensure purity standards for recovered materials (e.g., copper, aluminium, black mass).

Copper: ≥99.9% for reuse in wiring • Black mass: ≥95% metal oxides for cathode recycling • Plastics: Contamination <1% for pelletizing

Follow safety and environmental protocols for hazardous material handling.

PPE: Respirators, chemical gloves, eye protection • EU Battery Regulation (2023): 70% material recovery target • EPA RCRA: Hazardous waste handling (LiPF₆ disposal)

Document material streams for compliance with recycling regulations.

Material traceability (batch logs, COAs) • REACH/ROHS compliance reports