Lithium-Ion Battery Recycling Plant

— Turnkey Lithium-Ion Battery Recycling Plant

The lithium-ion battery recycling plant from YuSai is a turnkey, modular line that converts spent Li-ion batteries (pouch, cylindrical, prismatic, 3C and EV cells, plus electrode scrap) into saleable black mass, copper granules, aluminum granules, steel shells and separator film, with a metal & black mass recovery rate of 98%+ — and, with the optional hydrometallurgy phase, refines black mass into battery-grade lithium hydroxide, nickel sulfate, cobalt sulfate and manganese sulfate. The line features YuSai’s proprietary charged (discharge-free) crushing technology under inert-gas protection, eliminating brine-discharge wastewater and recovering the battery’s residual energy.Production capacity can be customized according to demand, every line is factory trial-run before shipment, with installation, training and 12-month warranty included.

Product Overview

YuSai Machinery (Henan YuSai Precision Machinery Co., Ltd., OEM/ODM since 1995) designs and builds complete lithium-ion battery recycling systems — from a single pretreatment line to a full “battery scrap → battery-grade chemicals” hydrometallurgical plant.

The plant is delivered in two buildable phases:

Phase 1 — Pretreatment & physical separation line (this page’s core): inert-gas-protected crushing, electrolyte drying, screening, diaphragm separation, magnetic separation, grinding and air-gravity separation. Outputs: black mass, copper granules, aluminum granules, steel shells, separator film (PP/PE).
Phase 2 — Hydrometallurgical refining (optional): lithium-first extraction, bipolar-membrane electrodialysis (BPED), solvent extraction and crystallization. Outputs: battery-grade LiOH·H₂O, NiSO₄·6H₂O, CoSO₄·7H₂O, MnSO₄·H₂O, cathode copper.

Who it is for:

Battery recyclers and scrap battery collectors upgrading from manual dismantling or brine discharging to automated, discharge-free processing
E-waste and PCB recyclers adding a lithium battery line
EV battery dismantlers and second-life operators processing end-of-life packs and modules
Investors building a new lithium battery recycling plant — pilot scale to 50,000 t/a class EPC projects (YuSai has delivered complete process engineering for a 50,000 t/a green recycling project treating 44,000 t/a of batteries and scrap)

Why the YuSai process is different: instead of copying the “discharge in salt water → shred → sell mixed black mass” route, YuSai applies technology proven in its precious-metal refining business (electrolysis, solvent extraction P204/P507/C272, RTO off-gas treatment) to batteries. The result: no discharge wastewater, 95%+ lithium recovery (industry average 50–70%), battery-grade hydroxide directly (no lithium carbonate intermediate), and closed-loop reagent recycling — economics and ESG compliance in one line.

Recycling Value Analysis

1. What your black mass is worth (real composition data)

Cobalt (Co): ~15.79% in ternary black mass (e.g., NCM811); < 0.5% in LFP black mass.
Nickel (Ni): 6.94 – 20% in ternary black mass (up to 60%+ in high-nickel systems like NCM811); absent in LFP.
Lithium (Li): ~2.5 – 4% in ternary black mass; ~3.19% in LFP black mass.
Manganese (Mn): ~4.82% in ternary black mass.
Copper / Aluminum: Cu 1.97 – 5%, Al ~5.13% — from current collectors and structural components.

Source: YuSai black mass market analysis (2025 data, China Nonferrous Metals Industry Association, SMM). Content varies by chemistry and brand.

2. Market and policy drivers (2025–2031 timeline)

Global lithium battery recycling market is projected to exceed US$10 billion by 2030, with China accounting for more than half; ternary + LFP waste arisings in China alone reached an estimated 176,000 t in 2025.
EU Battery Regulation (EU) 2023/1542 is now the compliance benchmark buyers ask about:
- Recycling efficiency for Li-ion batteries: 65% by end-2025/2026 → 70% by 2030/2031
- Material recovery: Li 50% (2027) → 80% (2031); Co/Ni/Cu 90% (2027) → 95% (2031)
- Battery Passport mandatory for EV/industrial batteries ≥ 2 kWh from 18 Feb 2027; recycled-content quotas for lithium from 2031 (6% → 12% by 2036)
Recycling vs mining life-cycle advantage (Stanford LCA): 58–81% lower GHG, 72–88% less water, 77–89% less energy — decisive for ESG reporting and green financing.
China’s EPR & battery traceability rules, plus US UN3480/3481 transport rules (air freight ≤ 30% state of charge), shape feedstock flows and logistics design.

3. Recovery-rate reporting by stage (honest, verifiable)

Copper & aluminum metals (Phase 1): ≥ 98% / ≥ 96% / ≥ 95% (Cu/Al/black mass grade) — typical vendor-verified range.
Black mass recovery: ≥ 98% (mechanical), up to 98.8% in optimized three-stage crushing + low-temperature pyrolysis.
Separator film: ≥ 98% — PP/PE for plastic recycling.
Hydrometallurgy metal recovery (Phase 2): Ni/Co 95–98%, Mn 90–95%, Li 80–95% — the lithium-first route lifts Li to >90%.
By-product value upgrade: Cu & Mn recovered as cathode copper + battery-grade sulfate instead of low-value slag — unique to YuSai’s extraction route.

Rates depend on feedstock mix and configuration; every claim is validated by free raw-material testing before purchase.

Applicable Materials

By format: pouch (soft-pack) cells · cylindrical cells (18650 / 21700 / 32650 etc.) · prismatic (steel / aluminum shell) cells · 3C (phone, laptop, power-bank) batteries

By chemistry: ternary NCM / NCA · LFP (LiFePO₄) · LMO · LCO

By source: EV / HEV packs and modules (after module-level dismantling or within validated pack envelope) · e-bike / e-scooter batteries · consumer electronics · ESS batteries · cell production scrap (defective cells, anode/cathode coated-foil offcuts) · nickel-containing residues (Phase 2)

Feed forms: whole cells or modules (discharge-free charged crushing within the validated feed envelope), dismantled cells, or electrode scrap. Sorting by shell type and chemistry at the line head optimizes every downstream step. Clear boundary: the line processes lithium-ion chemistries only — lead-acid, NiMH and other chemistries require dedicated equipment (we supply those lines too). Not every battery state can enter without pre-treatment; see section precautions (operation & safety notes) for the validated feed envelope (cell type, size, SOC, damage state, feed rate).

Product Structure (Main Equipment)

The Phase-1 line is a closed, fully automated train. Main equipment (benchmarked against the industry-standard 400–500 kg/h class line and upgraded with YuSai’s process design):

Belt conveyor (anti-static PVC) — metered, sealed feeding; 400 mm flight spacing, anti-static belt.
Inert-gas-protected crusher (single/double-shaft) — charged/discharge-free primary crushing under N₂ atmosphere with O₂ monitoring; shell disintegration to 3–5 cm.
Electrolyte drying unit (screw conveyor with 100–200 °C heating) — hot volatilization of electrolyte at ~120 °C, nitrogen carrier ~300 m³/h; vapor to off-gas system.
Hammer crusher (alloy steel + tungsten-carbide overlay) — breaks cathode/anode pieces to liberate metal from black mass.
Sealed pneumatic conveying (wind conveyor) — fully enclosed negative-pressure transfer between stations.
Linear screen (120 mesh) — primary classification, sealed dust-free.
Diaphragm extraction box + collector — Z-structure airflow suction removes separator film (PP/PE).
Circular vibrating screens (304 SS contact parts) — size classification, dual discharge.
Magnetic separation belt (3500–5000 GS) — removes steel shells/iron at ~1 m³/h.
Grinding machine (wear-resistant alloy discs) — mills electrode pieces (~20 mesh feed) to liberate fine powder; in-machine cooling keeps material < 50 °C.
Trommel screen (rotary, self-cleaning) — high-efficiency screening of ground material.
Air gravity separators (two-stage) — copper/aluminum separation by density; VFD airflow control.
Pulse-jet dust collectors (3 units, 99.99% efficiency) — negative-pressure dust collection at crusher, screens and mills; filter area 90 m² each.
PLC control cabinet — touch-screen central control; DCS/SCADA Ethernet interface reserved; 10% spare I/O.
Off-gas treatment system (optional/Phase 2 add-on) — bag filtration → semi-dry defluorination → RTO regenerative combustion → denitrification → alkali spray.

Optional upgrades: battery-powder pyrolysis furnace (rotary kiln, 450–550 °C, oxygen-free, removes PVDF binder & raises black mass grade) · black-mass washing & water-recycle unit (friction washing of shells/diaphragm, settling + full water reuse) · high-speed liberation machine (negative foil → ~0.2 mm copper granules, positive foil → ~0.5 mm aluminum granules, active coating → < 50 µm battery powder).

Phase 2 (hydrometallurgy) main units: selective/acid-roasting leaching reactors · filter press · neutralization & impurity-removal tanks · bipolar-membrane electrodialysis (BPED) stack · MVR evaporator & crystallizer · solvent-extraction battery (P204 / P507 / C272) · cyclone electrodeposition cells (cathode copper) · off-gas scrubbers.

Process Flow

Phase 1 — Pretreatment & physical separation (8 steps):

Feed → Inert crushing → Electrolyte drying → Screening & diaphragm removal → Magnetic separation → Grinding → Air-gravity Cu/Al separation → Black mass collection (dust & off-gas treated throughout)

Sorting & feeding. Cells are sorted by shell type and chemistry (LFP vs ternary/3C lines run in parallel for optimized parameters).
Inert-gas-protected crushing (charged, discharge-free). The crusher operates under a nitrogen atmosphere (target O₂ ≤ 2%) with vacuum/closed feeding, flame detection and interlock shutdown. Residual battery energy is released safely inside the furnace/pyrolysis stage and partly recovered as process heat — eliminating brine-discharge wastewater (saves ~80万 kWh electricity, 2,500 t wastewater per year vs brine discharging in our reference plant).
Electrolyte drying. Crushed material (3–5 cm) is heated to ~120 °C in the sealed drying conveyor; electrolyte volatilizes into the closed off-gas system (nitrogen carrier ~300 m³/h).
Screening & diaphragm separation. Linear + circular screens classify material; the diaphragm extraction box pulls out separator film (PP/PE) by airflow for separate sale.
Magnetic separation. Belt magnet (3500–5000 GS) removes steel shells and ferrous fragments.
Grinding & liberation. The mill liberates active material from foils; high-speed liberation (optional) aggregates negative foil into ~0.2 mm copper granules and positive foil into ~0.5 mm aluminum granules, with active coating reduced to < 50 µm battery powder.
Air-gravity separation (two-stage). Density separation splits copper and aluminum granules; final black mass is collected at 120–150 mesh.
Product collection & environmental chain. Black mass, copper, aluminum, steel shells and diaphragm film are collected and bagged separately; pulse dust collectors (99.99%) keep the whole line under negative pressure.

Optional — battery-powder pyrolysis: black mass is treated in the rotary kiln at 450–550 °C for 0.5–2 h under non-oxidizing atmosphere to decompose residual electrolyte organics and PVDF binder, raising black mass grade. Off-gas joins the treatment chain (bag filter → semi-dry defluorination → RTO → denitrification → alkali spray), with emissions far below EU/Chinese limits (measured: particulates 4.5 mg/m³, VOCs 55.8 mg/m³, HF 1.7 mg/m³ — vs 10 / 80 / 1.7 mg/m³ limits).

Phase 2 — Hydrometallurgical refining (YuSai's differentiating technology):

Lithium-first extraction: LFP powder undergoes selective oxidative leaching (H₂SO₄ + O₂/H₂O₂, ~3.5 h) — lithium dissolves while FePO₄ stays in residue; ternary powder is acid-roasted (350 °C, 0.5–1 h) then water-leached at ambient temperature (> 95% lithium sulfate recovered in one step). Lithium recovery 90–95% vs 50–70% in conventional back-end routes.
Battery-grade LiOH without carbonate intermediate: purified lithium sulfate feeds a bipolar-membrane electrodialysis (BPED) system producing LiOH solution + H₂SO₄ (recycled to leaching); evaporation-crystallization yields battery-grade LiOH·H₂O. No sodium-salt by-product, no carbonate step.
Ni/Co/Mn recovery: the leach residue enters two-stage countercurrent reduction acid leaching (60–90 °C) → copper removal (Lix984 extraction + cyclone electrodeposition → cathode copper) → impurity removal → P204/P507/C272 multi-stage solvent extraction separating Mn, Ni and Co → MVR evaporation-crystallization producing battery-grade NiSO₄·6H₂O, CoSO₄·7H₂O and MnSO₄·H₂O (ammonia-based saponification with closed-loop ammonia regeneration — no sodium sulfate by-product, ~¥12M/year saving vs sodium route).
Zero-discharge design: wastewater and reagents circulate; alkaline scrubber liquor is regenerated with Ca(OH)₂; all emissions measured well below standards.

Product Features

Charged, discharge-free crushing (patented process know-how) — no brine discharge, no discharge time, no discharge wastewater; inert-gas protection (O₂ ≤ 2%), sealed feeding, flame detection and interlock shutdown make it safe. Residual battery energy is released and partly reused — a genuine differentiator vs “discharge first” competitors.
98%+ recovery across fractions — black mass ≥ 98%, copper ≥ 96%, aluminum ≥ 95%, diaphragm ≥ 98% (vendor-verified range); black mass Cu+Al residue ≤ 1%.
Two-stage electrolyte treatment — low-temperature drying (~120 °C) volatilizes electrolyte at the source, then optional oxygen-free pyrolysis (450–550 °C) strips PVDF binder for higher black mass grade — no open burning, no dioxin risk.
Dry process with optional water-wash closed loop — water (when used for shell/diaphragm washing) is settled and fully reused; no process wastewater discharge.
Clean-air engineering — pulse dust collectors (99.99%), RTO + semi-dry defluorination + denitrification + alkali spray treat fluorinated organics; measured emissions far below EU/Chinese limits.
Phase 2 lifts margin dramatically — 95%+ lithium recovery (vs 50–70%), battery-grade LiOH·H₂O direct from BPED, battery-grade Ni/Co/Mn sulfates via extraction; reagent (ammonia, acid) closed-loop recycled.
Modular & upgradeable — buy the Phase-1 line today, add pyrolysis, washing or the full hydrometallurgy phase later without replacing front-end equipment; components (shredder, black-mass section) can upgrade existing third-party lines.
Fully automatic PLC / SCADA-ready — one-operator supervision, touch-screen control, reserved DCS Ethernet interface, 10% spare I/O, parameter storage and interlock protection.
Custom engineering — capacity 300 kg/h to multi-t/h; pilot, mid and 50,000 t/a class plant design; layout, voltage and emission limits engineered per site.
Turnkey delivery — factory trial run before shipment, installation & commissioning, operator training, 12-month warranty, lifetime support.

Technical Parameters

Phase 1 — Pretreatment & Physical Separation Line Parameters

Model class	Capacity	Installed power	Footprint (L×W×H)
YS-LBR-500	400 – 500 kg/h	~226 kW	30 × 10 × 4.8 m
YS-LBR-1000	800 – 1,200 kg/h	~350 – 450 kW	40 × 15 × 6 m

Model names are indicative; YuSai confirms the exact model code and specifications in the engineering proposal after free raw-material testing.

Phase 2 — Hydrometallurgical Refining Parameters

Parameter	Value
Crushing size (primary)	3 – 5 cm (inert atmosphere, O₂ ≤ 2%)
Electrolyte drying temperature	~120 °C (nitrogen carrier ~300 m³/h)
Pyrolysis temperature (optional)	450 – 550 °C, 0.5 – 2 h, oxygen-free
Screening mesh	120 mesh (linear) + rotary trommel
Magnetic separator	3500 – 5000 GS
Grinding output	~20 mesh feed → fine powder; material < 50 °C in-machine
Liberation size (optional)	Cu granules ~0.2 mm, Al granules ~0.5 mm, powder < 50 µm
Black mass fineness	120 – 150 mesh
Recovery (Phase 1)	Black mass ≥ 98%, Cu ≥ 96%, Al ≥ 95%, diaphragm ≥ 98%; Cu+Al in black mass ≤ 1%
Dust collection efficiency	99.99% (pulse-jet)
Off-gas treatment	Bag filter → semi-dry defluorination → RTO → denitrification → alkali spray
Measured emissions	Particulates 4.5 / VOCs 55.8 / HF 1.7 / SO₂ 13.3 / NOₓ 40.1 mg/m³ (reference plant)
Control system	PLC + touch screen, O₂/temperature monitoring, interlock, DCS interface reserved
Operators	1 – 2 per shift, fully automatic
Phase 2 hydrometallurgy	Li recovery > 90 – 95%; Ni/Co 95 – 98%; Mn 90 – 95%; products battery-grade LiOH·H₂O, NiSO₄·6H₂O, CoSO₄·7H₂O, MnSO₄·H₂O, cathode copper

Advantages

Real process engineering, not copied brochures — YuSai has delivered complete engineering for a 50,000 t/a green Li-ion battery recycling project (44,000 t/a batteries & scrap; outputs incl. 5,912 t/a battery-grade LiOH, 7,810 t/a CoSO₄, plus NiSO₄/MnSO₄). Page claims are backed by plant-level design data.
Precious-metal refining know-how applied to batteries — the same electrolysis, solvent-extraction (P204/P507/C272) and RTO off-gas technologies YuSai uses in gold/silver/PGM refining run in the battery hydrometallurgy phase. One engineering team, cross-validated chemistry.
Charged crushing edge — discharge-free feed removes the industry’s #1 bottleneck (brine discharge cost, incomplete discharge risk, labor) while inert-gas safety meets the strictest EU/US expectations.
95%+ lithium recovery & battery-grade LiOH direct — no lithium carbonate intermediate, no sodium sulfate by-product; economics validated (+¥63M/year upgrade margin in project studies).
Free raw-material testing — send 5–10 kg of your actual scrap; we run the pilot line and return a test report (recovery rates, purity, output composition) before you commit.
Full range under one roof — from single shredder upgrades to complete lines, pyrolysis furnaces, hydrometallurgy plants and downstream refining equipment; one vendor, one responsibility chain, no interface disputes.
Compliance-ready — CE/ISO documentation, EIA/permit guidance, and process design aligned with EU Battery Regulation 2023/1542 recovery targets (65%→70% efficiency, Li 50%→80%, battery passport) so your plant is future-proof.
Factory trial run & documentation — full-load test with video report before shipment; drawings, operation/maintenance manuals included.
Global delivery & responsive support — [Replace with delivered project cases: country, capacity, year]; 24/7 online support, spare parts at cost, lifetime consultation.

Quality System

YuSai operates a full-process quality management system across design, fabrication, assembly, testing and after-sales:

Design phase — every line is engineered from the customer’s raw-material test report; process calculations (capacity, power, O₂ control, emissions) are reviewed and locked before manufacturing. Pilot-plant data (50,000 t/a project design basis) informs scale-up.
Material & fabrication — incoming steel and electrical components inspected; certified welders with weld-seam records; anti-corrosion treatment on all process equipment; wear parts (crusher hammers, mill discs) in alloy steel with tungsten-carbide overlays.
Assembly & electrical — CE-compliant cabinets (CE documentation on request), color-coded wiring, protective earthing, safety interlocks; PLC with 10% spare I/O and DCS interface.
Factory trial run — no-load test, load test with representative material, recovery/purity sampling, 24 h continuous run for new configurations; video report and test certificate accompany delivery.
Documentation — operation manual, maintenance manual, layout/installation drawings, electrical diagrams, spare-parts list, CE declaration and export compliance documents where required.
Continuous improvement — field feedback feeds design updates; control-software and process upgrades offered to installed lines (lifetime upgrade support).

Service Process

Consultation & requirement analysis — raw-material type & daily tonnage, target outputs (black mass only, or battery-grade chemicals), budget, site conditions and local regulations.
Free raw-material test — 5–10 kg sample run on the pilot line; test report with recovery rates, purity and output composition.
Solution design & quotation — process design, plant layout, equipment list and commercial quotation with delivery schedule.
Manufacturing — fabrication in our own factory with scheduled progress updates (photos/videos) and stage inspections.
Factory trial run — full-line assembly and load test before shipment; video report provided.
Shipping & logistics — sea/air freight, container loading supervision, customs/export documentation (incl. UN38.3/battery transport guidance where relevant).
Installation & commissioning — engineers on site (or remote guidance), electrical connection and safety checks.
Operator training — hands-on training for operators and maintenance staff: operation, adjustment, safety procedures (charged-crushing envelope, inert-gas discipline), routine maintenance.
After-sales — 12-month warranty, spare parts at cost, 24/7 online support, lifetime process consultation.

Warranty & After-Sales Service

12-month warranty on the complete line against manufacturing defects (consumables/wear parts excluded per contract).
Spare parts at cost price for machine lifetime; recommended spare-parts list supplied.
24/7 online support — WhatsApp/WeChat/email with remote video diagnosis; most issues resolved within 24 h.
Lifetime technical consultation — process optimization, output tuning, free control-software upgrades.
Documentation package — manuals, drawings, electrical diagrams, video training files (English; local language on request).
Compliance support — EIA/permit application assistance; CE/ISO documentation; guidance on EU Battery Regulation reporting (recycling efficiency, material recovery, battery passport data chain).
On-site service — engineers dispatched for major maintenance/expansion; service agreements for large plants.

Precautions (Operation & Safety Notes)

Validated feed envelope (critical) — “discharge-free/charged crushing” applies only within the validated envelope: cell type & size, maximum state of charge (SOC), damage state and feed rate as defined in the engineering proposal. Batteries outside the envelope (e.g., damaged, swollen, or high-SOC packs beyond limits) must be pre-discharged or pre-dismantled. Laboratory results are not commercial guarantees.
Inert-gas discipline — crushing and pyrolysis stages require a reliable N₂ supply (generator, liquid tank or cylinders); O₂ monitors must read ≤ 2% during operation. Never run the crusher without the inert atmosphere engaged.
Feedstock screening — exclude foreign objects and non-Li-ion chemistries (lead-acid, NiMH). Leaking, swollen or damaged cells handled separately with extra caution.
Whole-pack EV processing — large EV packs usually require module-level dismantling first (remove shell, busbars, connectors, cooling and electronics) unless within the validated pack envelope.
Dust & black mass handling — black mass is fine, conductive and potentially reactive; store sealed and dry, away from ignition sources and moisture; comply with local rules for transport/export.
Fluorinated off-gas — electrolyte vapors contain fluorine; the treatment chain (defluorination → RTO → denitrification → alkali spray) must run whenever the line runs; monitor scrubber levels and activated carbon.
Operator training & PPE — trained operators only; goggles, gloves, anti-static clothing, respiratory protection; fire detection/suppression near crusher and dust collectors.
Routine maintenance — shredder blades/hammers, screens, filter bags, seals, O₂/temperature sensors per schedule; keep spare parts in stock.
Electrical safety — qualified electricians only; lock-out/tag-out before maintenance; proper earthing.
Regulatory compliance — verify waste import/export rules, EPR registration, environmental permits and (for EU sales) Battery Regulation 2023/1542 obligations before commissioning; YuSai provides guidance documents.

FAQ (Frequently Asked Questions)

Q1. What types of batteries can this plant process?
A: All common Li-ion formats — pouch, cylindrical (18650/21700/32650) and prismatic — and chemistries NCM/NCA, LFP, LMO, LCO, from EV packs, e-bikes, consumer electronics and ESS, plus cell production scrap and coated-foil offcuts. Lead-acid and NiMH need dedicated lines (YuSai supplies them too).

Q2. Do batteries need to be discharged before processing?
A: With our charged (discharge-free) crushing technology, cells within the validated feed envelope can be processed without brine discharging — no discharge wastewater, no incomplete-discharge risk. Batteries outside the envelope (damaged/swollen, very high SOC, oversized packs) are pre-discharged or pre-dismantled first. If you prefer the conservative route, we also offer a discharging unit.

Q3. What is the recovery rate?
A: Reported by stage: Phase 1 black mass ≥ 98%, copper ≥ 96%, aluminum ≥ 95%, diaphragm ≥ 98%, with Cu+Al in black mass ≤ 1%. Phase 2 hydrometallurgy: Ni/Co 95–98%, Mn 90–95%, lithium > 90–95% with our lithium-first route (industry back-end routes typically 50–70%). All claims verified by free raw-material testing.

Q4. What is the purity of the black mass / final chemicals?
A: Black mass 120–150 mesh with ≤ 1% Cu+Al residue. With Phase 2, products are battery-grade: LiOH·H₂O, NiSO₄·6H₂O, CoSO₄·7H₂O, MnSO₄·H₂O — meeting lithium-battery supply-chain specifications.

Q5. How much space is needed?
A: A 400–500 kg/h line is about 30 × 10 × 4.8 m (L×W×H); 1,000 kg/h class about 40 × 15 × 6 m; 2,000 kg/h about 55 × 18 × 6.5 m — plus material storage and, for Phase 2, a hydrometallurgy building. We provide a site layout drawing customized to your plot (see also our plant layout guide on request).

Q6. Can I start with a small line and expand later?
A: Yes — modular by design. Start with Phase 1 (300 kg/h pilot up), add pyrolysis, washing, or the full Phase 2 hydrometallurgy plant later without replacing front-end equipment. Existing third-party lines can also be upgraded with our shredders or black-mass section.

Q7. Can whole EV battery packs be crushed directly?
A: Only within the validated envelope (pack/module size, SOC, damage state). In most cases we recommend module-level dismantling first — remove shell, busbars, connectors and cooling components — which also improves product purity. We can supply the dismantling workstations.

Q8. Does the plant meet EU Battery Regulation 2023/1542 and environmental requirements?
A: Yes by design: the process targets the regulation’s recovery milestones (65%→70% Li-ion recycling efficiency; Li 50%→80%, Co/Ni/Cu 90%→95% material recovery; battery passport data chain from Feb 2027). Emissions are measured far below limits (particulates 4.5, VOCs 55.8, HF 1.7 mg/m³ at reference plant); CE/ISO documentation and EIA guidance provided.

Q9. What is the delivery time?
A: Standard Phase-1 lines are manufactured in about 40–50 working days after order confirmation, plus shipping; custom and Phase-2 plants per engineering schedule. Confirmed in the quotation.

Q10. How much does a lithium battery recycling plant cost?
A: It depends on capacity and configuration: The market price range for a complete physical production line is approximately US$75,000 to US$350,000. hydrometallurgy phase quoted separately. Send us your material and capacity for an itemized quotation with ROI analysis.

Q11. Can I buy only parts of the line to upgrade my existing recycling setup?
A: Yes — shredders, crushers, black-mass separation sections, dust collectors and PLC systems are sold separately to upgrade third-party lines. Tell us your current equipment and target output.

Q12. Does the plant handle LFP and NMC mixed feed?
A: The Phase-1 line processes both (parallel lines or adjustable crushing parameters); for Phase 2, LFP and ternary streams follow different lithium-first routes, so we recommend segregated feedstock for maximum battery-grade product quality — we design the sorting stage accordingly.