As global demand for electric vehicles and energy storage systems continues to rise, large-scale battery recycling is becoming a critical industry. A 1000kg/h lithium battery recycling plant is designed to efficiently process various types of used batteries, including EV battery packs, power batteries, and consumer lithium-ion batteries. But what exactly happens inside such a facility? Let’s walk through the complete process.
1. Pre-Discharging and Safety Treatment
Safety is always the first priority in lithium battery recycling. Before mechanical processing begins, batteries are sent to a controlled discharging system. This step eliminates residual electrical energy, reducing the risk of fire or explosion.
For large EV modules, manual or semi-automatic dismantling may be required to separate battery packs into smaller modules or cells. After discharging, the batteries are ready for the physical recycling stages.
2. Crushing and Primary Shredding System
The discharged batteries are fed into a heavy-duty shredder. In a 1000kg/h system, this shredder is designed with wear-resistant blades and operates under an inert or controlled environment to minimize oxidation and dust explosion risks.
The shredded material typically consists of mixed fractions:
- Aluminum and copper foils
- Plastic separators
- Steel casing materials
- Electrode materials (containing valuable metals)
A secondary crusher further reduces the material size, improving separation efficiency in the next stages.
3. Airflow and Physical Separation
After crushing, the material enters an advanced sorting system. Through a combination of airflow separation, vibration screening, and magnetic separation, the plant separates:
- Ferrous metals (steel)
- Non-ferrous metals (aluminum and copper)
- Plastic components
- Fine powder mixture (commonly known as “black mass”)
The 1000kg/h capacity ensures stable throughput while maintaining high separation efficiency, typically above 95% for metals.
4. Black Mass Collection and Refining
The most valuable output is black mass, which contains lithium, cobalt, nickel, and manganese compounds. This powder is collected through negative pressure systems and dust collectors to ensure environmental compliance.
Depending on customer requirements, the black mass can be:
- Directly sold to hydrometallurgical refineries
- Further processed for metal extraction
This stage determines the economic profitability of the plant.
5. Environmental Protection and Dust Control
Modern lithium battery recycling plants are equipped with pulse dust collectors, negative pressure systems, and gas purification units. These systems prevent fine powder leakage and ensure safe working conditions.
A well-designed 1000kg/h lithium battery recycling line not only focuses on high output but also on environmental sustainability and operator safety.
Final Thoughts
A 1000kg/h lithium battery recycling plant integrates discharging, shredding, separation, and collection into a fully automated production line. With proper design and process control, it delivers high recovery rates, stable performance, and strong economic returns.
As the lithium battery market continues expanding, investing in a large-capacity recycling plant is becoming not just an environmental responsibility—but also a strategic business opportunity. Visiting: https://www.solutionsforewaste.com/product/lithium-battery-recycling-plant/
Leave a Reply