XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 3241
the spent batteries to prevent resource exploitation (Hanisch
et al., 2015, Delucchi et al., 2014). This is also underlined
by the estimated return flow of LIBs of around 1.5 mil-
lion tonnes by 2040 (Neef et al., 2021). LIB recycling is
an option for regaining valuable materials and achieving
material sustainability. In recent years, various recycling
processes have been developed, which can be categorized
into mechanical, pyrometallurgical and hydrometallurgi-
cal processes (Werner et al., 2020). These can be combined
in different ways, depending on the product requirements.
The mechanical route is divided into the sub-processes of
crushing, classification and sorting (Werner et al., 2020).
During the process the electrodes are decoated. The gained
coating powder forms the so-called black mass, the most
valuable recycling product, which contains lithium metal
oxides and graphite. In order to fulfil the legal guidelines
of 95% for Co, Cu, and Ni and 80% for Li by 2031 (EU,
2020), the mechanical treatment is followed by flotation to
recover the graphite (Vanderbruggen, 2021). The remain-
ing metal oxides and phosphates are then recovered using
hydrometallurgical processes (Windisch-Kern et al., 2022).
However, LIBs differ not only in their chemical com-
position, but also in the geometric parameters and mate-
rials of the casing. It is therefore important to evaluate
processes for their stability and to check the behavior of
different battery types. To date, there are few studies that
analyze and balance the entire mechanical recycling pro-
cess. Wuschke et al. (Wuschke et al., 2019) found that steel
housings require higher specific stress energies than cells
with aluminum housings. Lyon et al. (Lyon et al., 2022a)
dealt with the efficiency of decoating as a function of the
machine. Wilke et al. (Wilke et al., 2023a), on the other
hand, conducted a comprehensive study of the first stage of
the recycling process for 10 different cell types. However, as
there has not yet been research into mechanical recycling of
the complete process chain of the mechanical recycling for
several different types, this is taken up in this study. In addi-
tion, this study shows for the first time recovery rates for
the metal components in the black mass for a mechanical
process and compares this to the requirements of the EU.
MATERIAL AND METHODS
Material
Five different battery types were analyzed in this study, the
characteristics of which are shown in Figure 1. As can be
seen two types are cylindrical (C2, C3) and three prismatic
(P1, P2, P6). One type (C2) has a steel casing whereas the
other four cells have an aluminum casing. Furthermore, the
cells differ in their chemistry with NMC111, NCA and
LFP as active material for the cathode. Further details can
be found in (Wilke et al., 2023a).
Methods
The cells were treated according to the process scheme
of the TU Bergakademie Freiberg (Wuschke, 2018). The
detailed scheme is shown in Figure 2. Prior to processing
the cells were overdischarged to a State of Charge (SoC) of
0% using an ohmic resistance. The process is divided into
two stages, each with three sub-processes: crushing, clas-
sifying and sorting. The first crushing step is divided into
pre-crushing and final crushing, depending on the cell size.
The larger prismatic cells were pre-shredded in a self-built
slow-rotating twin-shaft rotary ripper and/or rotary shearer
Figure 1. (a) Details of the investigated cell types and (b) photos of the investigated cells
the spent batteries to prevent resource exploitation (Hanisch
et al., 2015, Delucchi et al., 2014). This is also underlined
by the estimated return flow of LIBs of around 1.5 mil-
lion tonnes by 2040 (Neef et al., 2021). LIB recycling is
an option for regaining valuable materials and achieving
material sustainability. In recent years, various recycling
processes have been developed, which can be categorized
into mechanical, pyrometallurgical and hydrometallurgi-
cal processes (Werner et al., 2020). These can be combined
in different ways, depending on the product requirements.
The mechanical route is divided into the sub-processes of
crushing, classification and sorting (Werner et al., 2020).
During the process the electrodes are decoated. The gained
coating powder forms the so-called black mass, the most
valuable recycling product, which contains lithium metal
oxides and graphite. In order to fulfil the legal guidelines
of 95% for Co, Cu, and Ni and 80% for Li by 2031 (EU,
2020), the mechanical treatment is followed by flotation to
recover the graphite (Vanderbruggen, 2021). The remain-
ing metal oxides and phosphates are then recovered using
hydrometallurgical processes (Windisch-Kern et al., 2022).
However, LIBs differ not only in their chemical com-
position, but also in the geometric parameters and mate-
rials of the casing. It is therefore important to evaluate
processes for their stability and to check the behavior of
different battery types. To date, there are few studies that
analyze and balance the entire mechanical recycling pro-
cess. Wuschke et al. (Wuschke et al., 2019) found that steel
housings require higher specific stress energies than cells
with aluminum housings. Lyon et al. (Lyon et al., 2022a)
dealt with the efficiency of decoating as a function of the
machine. Wilke et al. (Wilke et al., 2023a), on the other
hand, conducted a comprehensive study of the first stage of
the recycling process for 10 different cell types. However, as
there has not yet been research into mechanical recycling of
the complete process chain of the mechanical recycling for
several different types, this is taken up in this study. In addi-
tion, this study shows for the first time recovery rates for
the metal components in the black mass for a mechanical
process and compares this to the requirements of the EU.
MATERIAL AND METHODS
Material
Five different battery types were analyzed in this study, the
characteristics of which are shown in Figure 1. As can be
seen two types are cylindrical (C2, C3) and three prismatic
(P1, P2, P6). One type (C2) has a steel casing whereas the
other four cells have an aluminum casing. Furthermore, the
cells differ in their chemistry with NMC111, NCA and
LFP as active material for the cathode. Further details can
be found in (Wilke et al., 2023a).
Methods
The cells were treated according to the process scheme
of the TU Bergakademie Freiberg (Wuschke, 2018). The
detailed scheme is shown in Figure 2. Prior to processing
the cells were overdischarged to a State of Charge (SoC) of
0% using an ohmic resistance. The process is divided into
two stages, each with three sub-processes: crushing, clas-
sifying and sorting. The first crushing step is divided into
pre-crushing and final crushing, depending on the cell size.
The larger prismatic cells were pre-shredded in a self-built
slow-rotating twin-shaft rotary ripper and/or rotary shearer
Figure 1. (a) Details of the investigated cell types and (b) photos of the investigated cells