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Lithium-ion Battery Pyrolysis Recycling Plant
Raw Materials:18650 cylindrical battery cells, steel-cased batteries, portable batteries, iron-cased lithium batteries, discharging lithium batteries, positive and negative electrode materials, etc.
Final Products: Black mass, copper granules, aluminum granules, steel shells
Main Part: Lithium battery pyrolysis furnace, shredder, crusher, magnetic separator, air-gravity separator, exhaust gas treatment system etc.
Product Description
Lithium-ion battery pyrolysis recycling plant (Temperature Control) mainly removes the electroltand organic waste from used lithium batteries through high-temperature pyrolysis technology. So that the black mass, copper, aluminum and iron in scrap lithium batteries can be separated and recycled efficiently.
Lithium-ion battery recycling value analysis
1. Precious Metal Composition Analysis
Key Metal Content (based on European black mass samples and Chinese recycling process data):
Cobalt (Co): ~ 15.79% in ternary lithium batteries (e.g., NCM811), <0.5% in LFP (lithium iron phosphate) black mass.
Nickel (Ni): 6.94%–20% in ternary black mass (up to 60%+ in high-nickel systems like NCM811).
Lithium (Li): ~3. 19% in LFP black mass, ~2.5%–4% in ternary black mass.
Copper (Cu)/Aluminum (Al): Cu: 1.97%–5%, Al: 5. 13% (from current collectors and structural components).
Others: Manganese (Mn) ~4.82%, fluorine (F), and impurities requiring wet-process purification.
2. Cost Analysis
Recycling Cost Structure (per ton of spent batteries):
LFP Batteries:
Recycling cost: ~¥8,500 ($1, 190)
Regenerated value: ~¥9,000 ($1,260)
Profit margin: 5%–10%
Breakdown: Disassembly (¥2,000), wet-process lithium extraction (¥3,000), environmental compliance (¥1,500).
Ternary Lithium Batteries:
Recycling cost: ~¥25,000 ($3,500) (including high-value metal extraction)
Co/Ni extraction: ¥ 12,000 (48%) via hydrometallurgy (acid leaching + solvent extraction).
Li extraction: ¥8,000 (32%) via lithium carbonate precipitation.
Environmental compliance: ¥3,000 (wastewater/gas treatment). Second-Life Applications:
Batteries with >80% capacity reused in low-speed vehicles/energy storage, reducing costs by 30% (but facing cell consistency challenges).
Applicable Raw Materials
Whether processing mixed lithium-ion batteries, Lithium Iron Phosphate (LiFePO₄), Lithium Cobalt Oxide (LCO), Nickel Cobalt Manganese (NMC) batteries, or automotive battery packs, Yusai Machinery’s lithium-ion battery pyrolysis recycling system employs thermal treatment, multi-stage crushing, and precision physical separation processes to maximize recovery efficiency while ensuring compliance with the strictest environmental and safety standards.
Applicable raw materials:18650, 21700, 26650 cylindrical cells, soft-pouch lithium-ion and Li-polymer batteries, prismatic aluminum-case and steel-case cells, lithium iron phosphate (LFP), ternary (NMC/NCA), lithium cobalt oxide (LCO) batteries.
Final Products
Black mass >99% (Rich in lithium, cobalt, nickel, and manganese)
Copper granules >98%
Aluminum granules >98%
Iron/steel >99%
All end products are ready for direct sale to hydrometallurgical refineries, smelters, or material manufacturers.
Lithium-ion Battery Pyrolysis Recycling Plant Working Process
Our lithium-ion battery pyrolysis recycling process combines mechanical processing with a carbonization/thermal treatment furnace (lithium battery pyrolysis furnace), all conducted in a fully automated, oxygen-free, and safe environment.
1. Battery Classification: Before processing, the batteries need to be classified. After classification, the batteries are fed into the machine.
2. Battery Discharging: Batteries are discharged to eliminate the risks of fire and explosion.
3. Battery Dismantling: It transports the discharged battery to a single-shaft crusher. The crushed battery is broken into small pieces of 2-3 cm under nitrogen protection, initially separating the battery casing, anode plate, cathode plate, and separator.
4. Thermal Treatment: The crushed material is conveyed by a screw conveyor into a dedicated lithium battery pyrolysis furnace (commonly known as a carbonization/heat treatment furnace). This furnace operates in an oxygen-free environment at a high temperature of 400-650°C. The generated electrolyte waste gas is sent to the electrolyte secondary combustion chamber, and then treated by a tail gas treatment system (scrubber + activated carbon + catalytic combustion system) to ensure compliance with environmental protection requirements.
5. Gravity Separation (Shell Sorting): The thermally treated mixture is fed into a gravity separator, which utilizes weight differences to effectively sort and remove the heavy battery outer shells (iron/stainless steel).The Magnetic Separator then recovers the steel shell (iron shell) from the mixture of shells.
6. Rotary Screening: The heavy material moves to the Rotary Drum Screen to screen out black mass. Material above the screen is conveyed to the Crusher with Noise Proof Room, which breaks the anode and cathode metal pieces and knocks down the black mass.
7. Air Separation: Air Separation System separates the copper granules and aluminum granules with remarkable precision, yielding clean, sellable metal scrap.
8. Exhaust Gas Treatment System: A comprehensive environmental control system captures the off-gases from the pyrolysis and crushing stages. Using secondary combustion, cooling , dust collector, defogger and activated carbon scrubbers, it neutralizes VOCs and acid gases, ensuring your plant meets all local emission standards.The floating black substance was collected by the cyclone separator.
9. Nitrogen Protection System: Safety is non-negotiable. Throughout the shredding, crushing, and sorting stages, an automated Nitrogen (N2) inerting system displaces oxygen, effectively eliminating the risk of combustion or explosion.
Lithium battery pyrolysis recovery equipment features advantages
1.Unmatched Cell Compatibility
Our lithium battery recycling plant is engineered to handle a wide spectrum of spent batteries, regardless of their complexity, shape, or chemistry:
Cell Form Factors: Fully compatible with Cylindrical cells (e.g., 18650, 21700, 32650), Pouch cells, and Prismatic hard-shell cells.
Battery Chemistries: Covers Lithium Iron Phosphate (LFP), Nickel Manganese Cobalt (NMC/NCA), and Lithium Cobalt Oxide (LCO).
Application Scenarios: Supports large-scale processing ranging from small consumer electronics (phones, laptops) to massive Electric Vehicle (EV) battery packs and Energy Storage Systems (ESS).
2.High-Purity Black Mass Recovery
The core value of lithium battery recycling lies in the “Black Mass.” Our process utilizes multi-stage precision sorting to ensure maximum economic returns:
Black Mass Purity: Leveraging advanced sorting technology, the recovery purity of black mass exceeds 98%.
Multi-Component Separation: The system efficiently isolates high-purity copper foil, aluminum foil, plastic separators, and casing metals (Aluminum/Iron).
Output Value: The recovered black mass is rich in rare metals like lithium, cobalt, and nickel, which can be directly fed into hydrometallurgical processes for a true closed-loop resource cycle.
3.Industrial Safety & Fire Protection
Addressing the flammable and explosive nature of lithium batteries, we have integrated an industry-leading safety control system:
Nitrogen Protection System: An inert gas (Nitrogen) is injected during the fully enclosed crushing process to keep oxygen levels below the safety threshold, fundamentally eliminating fire and explosion risks.
Sealed Environment: The entire crushing and sorting sequence operates under negative pressure in a sealed environment, effectively preventing the leakage of electrolyte volatile gases.
Eco-friendly Treatment: Equipped with pulse dust collectors and acid gas scrubbing towers, the system ensures that exhaust emissions strictly comply with international environmental standards (ISO/CE certified).
Technical Parameters
| Model | PCS1000 | PCS1500 |
| Capacity | 800-1000kg/h | 1500-1600kg/h |
| Power | 480Kw | 530Kw |
| size | 50*8*6(m) | 60*8*6(m) |
| weight | 15(ton) | 30(ton) |
Note:
1. Working voltage:380±10V(415V ,440V also can be custom);
2. The parameters and configurations above are for reference only. We can provide customized solutions and related lithium battery recycling machines based on different requirements. Please feel free to contact us anytime to discuss your specific needs.
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