Lithium-ion Battery Recycling System
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Lithium-ion Battery Recycling System – ToronLi-ion™
The ToronLi-ion™ lithium-ion battery recycling system recovers black mass, copper granules, aluminum granules, separator film, and casing material from used battery cells, modules, and electrode manufacturing scrap. Its integrated process combines physical crushing, thermal treatment, multi-stage screening, air classification, and gravity separation under centralized control. Processing capacities range from 500 to 2,000 kg/h, with annual line capacities configurable from 500 to 20,000 tons. Each processing stage produces a separated material fraction suitable for commercial sale.
Safely processing charged cells is one of the primary challenges in lithium-ion battery recycling. The initial crushing stage takes place inside a sealed four-shaft chamber designed for nitrogen filling. This creates an oxygen-deficient environment around the cutting area to reduce the conditions required for ignition. Multiple safety measures protect the charged-battery crushing process, while the low-speed, high-torque drive maintains controlled cell deformation. As a result, batteries can enter the processing line without requiring a separate preliminary discharge operation.
The modular design allows individual processing stages to operate independently while remaining integrated into the complete production sequence. Facilities can initially install the crushing and sorting sections, then expand their capabilities with pyrolysis, aluminum granule refining, black powder carbonization, or separator washing as processing requirements increase. A PLC-based central control system manages the connected modules and provides communication interfaces for integration with plant-level DCS systems. Independent module access also simplifies inspection and maintenance.
Lithium-ion Battery Recycling System – ToronLi-ion™ Applications
The ToronLi-ion™ recycling system supports both dedicated battery recyclers supplying black mass to refining facilities and battery manufacturers recovering materials from their own production waste.
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Electric Vehicle Battery Recycling: Processes end-of-life traction battery packs, modules, and cells into separated metal and black mass fractions for subsequent refining.
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Black Mass Production for Refiners: Provides hydrometallurgical and pyrometallurgical processing facilities with screened cathode and anode powders featuring consistent particle sizes.
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Consumer Electronics Battery Recovery: Processes lithium-ion cells from mobile phones, laptops, and portable electronic devices collected through mixed recycling streams.
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Battery Manufacturing Scrap: Recovers valuable materials from positive and negative electrode sheets, laminates, and nonconforming production output generated by gigafactory operations.
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Electrode Pole Piece Processing: Removes coating materials from copper and aluminum foil, allowing both metals to be recovered as clean granules for commercial use.
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LFP Battery Recycling: Processes lithium iron phosphate batteries, recovering both separated powder and current collector foils as valuable material streams.
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Energy Storage System Decommissioning: Handles retired grid-scale and commercial energy storage batteries that have reached the end of their service life.
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Copper and Aluminum Recovery: Produces separated metal granules through integrated air classification and specific gravity sorting processes.
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Separator Film Recovery: Preserves and recovers diaphragm material when the drying stage operates below the film damage threshold.
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Automotive Dismantling Operations: Expands existing vehicle and component recovery operations with dedicated lithium-ion battery processing capabilities.
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Hazardous and Industrial Waste Contractors: Enables contractors to process lithium batteries within their own facilities instead of transporting cells to external processing providers.
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Cathode Material Producers: Supports closed-loop material recovery by processing internal production scrap and returning recovered powder to the material supply chain.
Lithium-ion Battery Recycling System – ToronLi-ion™ Key Features
The ToronLi-ion™ system integrates nitrogen-protected crushing, staged thermal processing, and three distinct physical separation methods. Its modular configuration allows individual processing units to be selected or excluded according to the characteristics of the incoming battery material.
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Nitrogen-Protected Four-Shaft Crushing: Features a sealed cutting chamber designed for nitrogen filling, allowing charged cells to be shredded in an oxygen-deficient atmosphere to reduce fire risks.
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Processing Without Prior Discharge: Accepts charged battery cells directly, eliminating the separate discharge operation and reducing associated material-handling time.
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Low-Speed, High-Torque Shredder Drive: Uses slow shaft rotation and high torque to process battery modules and cells with reduced noise and less heat generation than high-speed cutting systems.
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Automatic Reverse and Overload Protection: PLC-controlled starting, stopping, reversing, and overload responses automatically address blockages without requiring operators to access the cutting chamber.
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Electrolyte Condensation and Recovery: Maintains drying temperatures between 100 and 150 degrees Celsius to capture electrolyte for recovery rather than allowing it to escape through the exhaust stream.
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Separator Film Preservation: Keeps the drying temperature below the separator film damage threshold, allowing diaphragm material to remain suitable for subsequent sorting and commercial recovery.
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Low-Temperature Cracking Furnace: Operates between 450 and 600 degrees Celsius to decompose binders and residual organic compounds, improving the purity of recovered black powder.
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Three-Stage Exhaust Treatment: Combines catalytic combustion, alkali washing and spraying, and activated carbon polishing to bring treated exhaust gas into compliance with emission requirements.
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Coating Stripping Fine Crusher: Provides extended material residence time inside the crushing chamber to separate black powder from foil while converting copper and aluminum into granules for cleaner metal separation.
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Combined Static and Dynamic Screening: Integrates linear screens, circular vibrating screens, swing screens, and airflow sorting screens to improve black powder recovery.
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Air Sorting at 99 Percent: Uses airflow classification to separate lightweight film from heavier metal fractions, achieving a supplier-reported separation ratio of 99 percent.
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Gravity Sorting at 99 Percent: Separates copper and aluminum granules according to their specific gravity, with a supplier-reported sorting ratio of 99 percent.
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Fully Sealed Conveying: Uses enclosed material transfer between processing stages to contain dust and maintain material control throughout the production line.
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Negative Pressure Dust Extraction: Maintains negative pressure throughout the process using centralized dust extraction, helping contain powder within the system and maintain a clean working environment.
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Siemens PLC Central Control: Coordinates the complete processing sequence through a centralized control program, with Ethernet, MODBUS TCP/IP, OPC, PROFINET, and DP communication interfaces available for DCS integration.
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Branded Electrical Components: Features control cabinets equipped with ABB, Schneider, and Siemens electrical components to support parts availability and familiar maintenance procedures.
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Modular Architecture: Allows individual processing units to operate independently, enabling phased installation and future capacity or capability expansion without reconstructing the entire production line.
Theory and Method
Lithium-ion battery components can be separated effectively through mechanical processing because their physical properties respond differently to crushing. Cathode and anode coatings consist of brittle particulate materials bonded to ductile metal foils. When crushing tears the foil into granules, the brittle coating simultaneously fractures and separates into fine particles. This creates two material groups with substantially different particle-size distributions, making screening an effective separation technique. Battery casings and pole lugs remain relatively large and heavy, allowing them to be removed from the material stream during the initial size and density separation stages.
Thermal processing removes substances that mechanical separation cannot adequately address. Battery electrolyte consists of volatile organic carbonate compounds. Heating the crushed material to temperatures between 100 and 150 degrees Celsius causes the electrolyte to vaporize, allowing it to be collected through condensation for recovery. This temperature range remains below the degradation threshold of the separator film, preserving the diaphragm for subsequent sorting. The material is then transferred to the cracking furnace, where temperatures between 450 and 600 degrees Celsius break down the polymer binders that attach electrode coatings to the metal foils. Residual organic compounds are also decomposed during this stage, reducing potential contamination in the recovered powder.
The final separation stages rely on differences in material density and aerodynamic behavior. Air classification uses terminal velocity to distinguish lightweight materials from heavier fractions. Separator film and plastic particles are carried upward by the airflow, while denser metal granules settle downward. The supplier reports a separation ratio of 99 percent for this process.
Copper and aluminum are subsequently separated according to their specific gravity. Copper has a density of approximately 8.96 grams per cubic centimeter, compared with approximately 2.70 grams per cubic centimeter for aluminum. During gravity separation, a specialized sieving machine fluidizes the bed of metal granules, allowing the denser copper particles to migrate downward and separate into distinct layers from the aluminum. The supplier reports a sorting ratio of 99 percent for this separation process.
Lithium-ion Battery Recycling System - ToronLi-ion™ Technical Specifications
System Overview
| Parameter | Specification |
|---|---|
| System Type | Physical crushing, thermal treatment, and sorting line for lithium-ion batteries |
| Hourly Throughput | 500 to 2,000 kg/h |
| Annual Processing Capacity | 500 to 20,000 tons per year |
| Installed Power | 150 to 1,280 kW |
| Processable Feedstock | Power battery packs and modules, consumer electronics lithium cells, positive and negative electrode sheets, laminates, battery production scrap |
| Output Materials | Black mass powder, copper granules, aluminum granules, separator film, battery casing and shell material, recovered electrolyte |
| Coarse Crushing Atmosphere | Sealed chamber with nitrogen filling capability |
| Drying Temperature | 100 to 150 °C |
| Cracking Furnace Temperature | 450 to 600 °C |
| Air Separation Ratio | 99 percent (supplier stated) |
| Gravity Sorting Ratio | 99 percent (supplier stated) |
| Control System | Siemens PLC with central control cabinet |
| Communication Interfaces | Ethernet with independent IP address, MODBUS TCP/IP, OPC, PROFINET, DP |
| Electrical Components | ABB, Schneider, Siemens |
| Dust Control | Fully sealed conveying with negative pressure central dust removal |
| Layout | Modular, floor space customized to the site |
| Reference Installations | 1,000 kg/h, 1,500 kg/h, and 2,000 kg/h lines in operation |
Machine Line-Up
The system consists of the following modules, each detailed according to its function, operating principle, and available technical parameters.
1. Sealed Conveying System
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Material is transferred between processing stages through fully enclosed conveying systems. Sealed construction contains powder and vapor within the production line, preventing their release into the facility. Working in conjunction with the negative-pressure dust extraction system, the enclosed conveyors help maintain a clean and controlled working environment. |
| Parameter | Specification |
|---|---|
| Function | Enclosed material transfer between processing stages |
| Construction | Fully sealed conveying enclosure |
| Process Benefit | Contains dust and vapor, reduces material loss between stages |
| Integration | Operates under the negative pressure of the central dust removal system |
| Configuration | Routing and length set by plant layout |
2. Coarse Crushing System
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The coarse crushing stage uses a four-shaft shredder specifically designed for lithium-ion battery processing. Its housing features four-layer sealing, allowing the chamber to be filled with nitrogen to reduce oxygen levels around the cutting zone and minimize ignition risks when processing charged battery cells. The shredder rapidly reduces battery cells and modules into flake-sized material. Microcomputer-based controls automatically manage starting, stopping, reversing, and overload protection. Its low-speed, high-torque drive also ensures quiet operation during crushing. |
| Parameter | Specification |
|---|---|
| Function | Primary size reduction of lithium battery cells and modules into flake material |
| Rotor Configuration | Four-shaft shredder |
| Chamber Sealing | Four-fold tightness, suitable for nitrogen filling |
| Atmosphere Control | Gas protection design for crushing charged batteries |
| Safety Provision | Multi-level protection measures against fire risk |
| Drive Characteristics | Low speed, high torque, low noise |
| Control Functions | Automatic start, stop, reverse, and overload reverse |
| Electrical Control | Designed to align with European CE requirements (certificate number not supplied) |
| Output Form | Flake material for downstream thermal treatment |
3. Drying System
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Crushed battery material undergoes drying at temperatures between 100 and 150 degrees Celsius. During this stage, the electrolyte and other organic compounds vaporize and are subsequently condensed for recovery. This temperature range remains below the separator film degradation threshold, preserving the diaphragm's integrity so it can be separated and recovered as a valuable material fraction during subsequent sorting. |
| Parameter | Specification |
|---|---|
| Function | Volatilization and recovery of electrolyte and organic matter |
| Operating Temperature | 100 to 150 °C |
| Electrolyte Handling | Condensed and recovered as a product stream |
| Separator Condition | Diaphragm remains undamaged at this temperature |
| Process Purpose | Prepares material for sorting and reduces load on the exhaust system |
4. Cracking and Pyrolysis System
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The cracking furnace uses a low-temperature pyrolysis process operating between 450 and 600 degrees Celsius. At this temperature, residual organic compounds and impurities in the crushed battery material decompose, including the polymer binder that attaches electrode coatings to the current collector foil. Breaking down and removing these binders improves the purity of the black powder recovered during subsequent processing stages. |
| Parameter | Specification |
|---|---|
| Function | Thermal decomposition of organic matter and residual impurities |
| Furnace Temperature | 450 to 600 °C |
| Process Type | Low-temperature cracking |
| Target Material | Binder and organic impurities in crushed battery material |
| Process Benefit | Raises the quality of recovered black powder |
5. Exhaust Gas Treatment System
Exhaust gases generated during drying and cracking are processed through a three-stage gas treatment system. Catalytic combustion breaks down combustible organic compounds, followed by alkali washing and spraying to neutralize acidic and harmful substances. Activated carbon treatment then provides final gas purification before the treated stream is discharged.
| Parameter | Specification |
|---|---|
| Function | Removal of harmful substances from process exhaust gas |
| Stage 1 | Catalytic combustion |
| Stage 2 | Alkali washing and spraying |
| Stage 3 | Activated carbon purification |
| Discharge Condition | Treated to meet applicable emission requirements |
6. Secondary Crusher
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A high-speed, single-shaft hammer crusher performs the intermediate size-reduction stage. Its hammering action breaks down bulk material remaining after thermal treatment, preparing the material stream for subsequent specific gravity separation of heavy components, including steel casings and pole lugs. |
| Parameter | Specification |
|---|---|
| Function | Intermediate size reduction after thermal treatment |
| Crusher Type | High-speed single-shaft hammer crusher |
| Target Material | Bulk material remaining in the process stream |
| Process Purpose | Prepares heavy fractions such as steel shells and pole lugs for gravity sorting |
7. Fine Crusher
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The fine crusher completes the separation of electrode coatings from their metal foils. Material remains inside the crushing chamber for an extended residence time rather than passing through immediately. Repeated crushing action removes black powder from the pole pieces while breaking copper and aluminum foils into granules. This granulation process enables effective separation of copper and aluminum during the subsequent sorting stages. |
| Parameter | Specification |
|---|---|
| Function | Stripping of black powder from electrode foil and granulation of current collectors |
| Residence Behavior | Extended retention in the crushing cavity |
| Output Form | Copper granules, aluminum granules, liberated black powder |
| Process Purpose | Enables clean copper and aluminum separation downstream |
8. Screening System
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Screening is performed using multiple machine types selected according to the processing configuration. Linear screens, circular vibrating screens, swing screens, and airflow sorting screens combine static and dynamic separation methods to extract black powder thoroughly from the material stream through multiple screening stages. |
| Parameter | Specification |
|---|---|
| Function | Separation of black powder from granule and coarse fractions |
| Screen Types | Linear screen, circular vibrating screen, swing screen, airflow sorting screen |
| Screening Method | Combined static and dynamic screening |
| Selection Basis | Screen type chosen according to the process route |
| Process Benefit | Raises the recovery rate of black powder |
9. Air Separation System
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The air separation system uses a controlled airstream to classify materials according to their weight and aerodynamic properties. Lightweight materials are carried along with the airflow, while heavier fractions resist the air current and fall. This process separates separator film and plastic from metal granules and casing fragments. |
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| Parameter | Specification |
|---|---|
| Function | Separation of light material from heavy material |
| Working Principle | Airflow direction and terminal velocity difference |
| Separation Ratio | 99 percent (supplier stated) |
| Light Fraction | Separator film, plastic, lightweight residue |
| Heavy Fraction | Metal granules, casing and shell fragments |
10. Gravity Sorting System
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Gravity separation completes the metal recovery process. Any remaining black powder is first removed from the copper and aluminum granules through screening. The granules then enter a specific gravity sieving machine, which separates the two metals based on their difference in material density. |
| Parameter | Specification |
|---|---|
| Function | Separation of copper granules from aluminum granules |
| Working Principle | Specific gravity difference under sieving action |
| Preliminary Step | Sieving of residual black powder from the granule stream |
| Sorting Ratio | 99 percent (supplier stated) |
| Output Fractions | Copper granules, aluminum granules, recovered black powder |
11. Powder Conveying System
Recovered black powder is transported through a dedicated conveying system, separate from the main material handling route. This isolated transfer process minimizes contamination risks and keeps fine powder contained throughout handling.
| Parameter | Specification |
|---|---|
| Function | Dedicated transport of recovered black powder |
| Construction | Enclosed powder handling route |
| Process Purpose | Protects product purity and contains fine material |
| Discharge | To collection, packing, or further processing |
12. Central Dust Removal System
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A centralized dust extraction system maintains negative pressure throughout the processing line. Air is drawn inward at each material transfer point to prevent powder from escaping into the work area, while collected fine particles are returned to the product stream for recovery. |
| Parameter | Specification |
|---|---|
| Function | Dust capture and workspace air quality control |
| Operating Principle | Negative pressure across the process line |
| Coverage | Transfer points, crushing, screening, and sorting stages |
| Process Benefit | Reduces dust escape and recovers captured fine material |
13. Central Control System
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The entire process is managed through a Siemens PLC-based electrical control system. The controller includes an Ethernet port with an independent IP address and supports MODBUS TCP/IP, OPC, and PROFINET protocols, along with a DP communication interface. These communication capabilities enable integration with the plant's DCS and provide the corresponding variable table. Electrical control cabinets are equipped with ABB, Schneider, and Siemens components. |
| Parameter | Specification |
|---|---|
| Function | Process sequence control, monitoring, and plant integration |
| Controller | Siemens PLC |
| Network Interface | Ethernet port with independent IP address |
| Supported Protocols | MODBUS TCP/IP, OPC, PROFINET, DP |
| Plant Integration | DCS communication with variable table provided |
| Component Brands | ABB, Schneider, Siemens |
| Cable Management | Cable trays laid according to site requirements |
| Operation | Centralized automatic control across all modules |
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