Lithium-Ion Electrode Scrap Recycling Line
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Lithium-Ion Electrode Scrap Recycling Line – ToronLi-ion™ ESR
The ToronLi-ion™ ESR lithium-ion electrode scrap recycling line recovers coated cathode and anode sheets, stacking scrap, and laminate offcuts, separating them into reusable copper foil, aluminum foil, and electrode powder. Its crushing, separation, and purification stages operate in a fully automated sequence with minimal manual handling. According to supplier data, the system achieves a recovery rate of more than 95% of reusable materials. Battery manufacturers can use this line to recover internal production scrap and return valuable materials to the supply chain instead of paying for coated foil disposal.
Unlike whole-cell recycling, electrode scrap processing focuses on separating the coating from the current collector. A polymer binder holds the electrode coating to the metal foil, making delamination rather than cell dismantling the primary recovery challenge. The ToronLi-ion™ ESR addresses this through staged mechanical processing combined with thermal treatment to break down the binder and remove residual organic matter. During crushing, copper and aluminum foils form granules instead of breaking down into powder, creating the particle size and density differences required for effective downstream separation.
The recovered electrode powder retains valuable metals from the original coating, including lithium, cobalt, and nickel, making it suitable for further hydrometallurgical extraction by refiners. Separately recovered copper and aluminum granules are ready for direct sale. A centralized PLC controls the entire processing sequence, reducing operator involvement while maintaining consistent performance across shifts. Automated operation also minimizes exposure to fine powder, supporting material purity and improved workplace conditions.
Lithium-Ion Electrode Scrap Recycling Line – ToronLi-ion™ ESR Applications
The ToronLi-ion™ ESR recycling line is designed for battery manufacturers producing coated electrode scrap and recycling facilities processing pole piece materials as a dedicated waste stream.
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Battery Gigafactory Production Scrap: Recovers coated foil rejected during coating, calendering, and slitting operations, allowing valuable materials to reenter the supply chain rather than being discarded.
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Electrode Coating Line Rejects: Processes off-spec electrode sheets generated during production startup, coating defects, and routine material changeovers.
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Cathode Sheet Recovery: Separates aluminum current collectors from cathode coatings, recovering both the metal foil and metal-bearing powder fraction.
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Anode Sheet Recovery: Separates copper foil from graphite coating to produce clean copper granules and recovered anode material.
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Stacking and Laminating Scrap: Processes laminate trimming waste and stacking offcuts with electrode coating on both surfaces.
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Slitting and Calendering Offcuts: Handles narrow edge trimmings and roll ends generated throughout electrode converting operations.
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Cathode Material Producers: Supports internal material recovery by returning off-spec coated electrode material to the powder supply.
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Copper Foil Recovery: Produces coating-free granulated copper suitable for direct sale to metal buyers.
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Aluminum Foil Recovery: Processes coated aluminum current collectors into clean granules through the same recovery process.
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Black Powder Supply to Refiners: Produces screened electrode powder with consistent particle sizes for subsequent hydrometallurgical processing.
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Pilot Line and R&D Scrap: Handles small-volume development materials with varying coating chemistries between production batches.
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Contract Electrode Manufacturers: Provides recycling capabilities for electrode scrap generated across multiple customer production programs.
Lithium-Ion Electrode Scrap Recycling Line – ToronLi-ion™ ESR Key Features
The ToronLi-ion™ ESR combines multi-stage crushing, thermal binder removal, and three distinct separation principles. Individual processing modules can be configured according to the electrode chemistry and scrap volume at the installation site.
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Recovery Above 95 Percent: Supplier data indicates that more than 95% of the input material is recovered as reusable output across the combined product streams.
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Fully Automated Sequence: Automated processing requires minimal manual intervention, helping reduce labor costs and limit operator exposure to fine powder.
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Precision Electrode Crushing: Crushing mechanisms are designed specifically for coated electrode sheets rather than general scrap, preserving foil integrity while releasing the electrode coating.
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Coating Stripping Fine Crusher: Extended material residence inside the crushing chamber removes powder from pole pieces and converts copper and aluminum foil into granules.
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Sealed Four-Shaft Crushing Chamber: The box-shaped chamber features four-fold sealing and supports nitrogen filling to reduce ignition risks when processing reactive materials.
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Low-Speed High-Torque Drive: Slow shaft rotation combined with high torque cuts coated electrode sheets quietly while minimizing the heat buildup associated with faster cutting systems.
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Automatic Reverse and Overload Protection: PLC-controlled starting, stopping, reversing, and overload protection help clear material blockages without requiring the cutting chamber to be opened.
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Controlled Drying Stage: Operating temperatures between 100 and 150°C remove organic matter without damaging the film material required for subsequent separation.
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Low-Temperature Cracking Furnace: Processing temperatures between 450 and 600°C decompose polymer binders and residual organic compounds, improving recovered powder quality.
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Three-Stage Exhaust Treatment: Catalytic combustion, alkali washing and spraying, and activated carbon polishing treat exhaust gases to meet emission requirements.
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Static and Dynamic Screening Combined: Linear screens, circular vibrating screens, and airflow sorting screens work together to achieve thorough powder separation.
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Air Sorting at 99 Percent: Airflow classification separates lightweight materials from heavier fractions with a supplier-reported separation ratio of 99%.
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Gravity Sorting at 99 Percent: Specific gravity screening separates copper granules from aluminum granules with a supplier-reported sorting ratio of 99%.
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Siemens PLC Central Control: A centralized Siemens PLC program controls the complete process. Ethernet, MODBUS TCP/IP, OPC, PROFINET, and DP interfaces are provided for DCS integration.
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Branded Electrical Components: Electrical control cabinets feature ABB, Schneider, and Siemens components, supporting parts availability and convenient servicing.
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Reduced Environmental Load: Recycling coated electrode foil reduces battery manufacturing waste sent for disposal while returning valuable metal materials to production.
Theory and Method
Lithium-ion electrode scrap recycling primarily involves separating the electrode coating from its metal current collector. The coating consists of particulate material bonded to the foil surface by a polymer binder, typically polyvinylidene fluoride on the cathode side. This bonding makes conventional crushing insufficient because the underlying foil deforms instead of fracturing. The ToronLi-ion™ ESR combines mechanical processing and thermal treatment to overcome this challenge. Heat decomposes the binder and weakens its bonding strength, while repeated crushing applies shear forces that remove the loosened coating from the metal surface.
The different physical properties of the foil and coating enable subsequent separation. Copper and aluminum are ductile metals that tear into curled granules during crushing rather than becoming fine powder. Electrode coatings, in contrast, are brittle and break down into fine particles. This produces two material fractions with significantly different particle sizes, allowing screening equipment to separate electrode powder from metal granules. Extended residence time inside the fine crusher further removes residual coating while shaping the metal granules into their final form.
The final metal separation stage uses differences in material density. Copper has a specific gravity of approximately 8.96 g/cm³, compared with approximately 2.70 g/cm³ for aluminum. This substantial difference makes gravity-based separation effective. During specific gravity sieving, the granule bed becomes fluidized, allowing denser copper particles to move downward and separate from aluminum through stratification. The supplier-reported sorting ratio for this process is 99%. Air classification handles the lighter material fractions, separating film and other low-density residues with a reported separation ratio of 99%.
Lithium-Ion Electrode Scrap Recycling Line - ToronLi-ion™ ESR Technical Specifications
System Overview
| Parameter | Specification |
|---|---|
| System Type | Automated crushing, thermal treatment, and sorting line for lithium battery electrode scrap |
| Processable Feedstock | Cathode and anode electrode plates, pole pieces, stacking and laminate scrap, coated foil offcuts |
| Output Materials | Electrode powder, copper granules, aluminum granules, separated film material |
| Recovered Metal Content | Electrode powder carrying lithium, cobalt, and nickel for downstream refining |
| Material Recovery Rate | Over 95 percent of reusable material (supplier stated) |
| Crushing Chamber Sealing | Four-fold tightness, suitable for nitrogen filling |
| Drying Temperature | 100 to 150 °C |
| Cracking Furnace Temperature | 450 to 600 °C |
| Air Sorting 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 |
| Automation Level | Fully automated process with minimal manual intervention |
| Layout | Modular, floor space customized to the site |
Machine Line-Up
The recycling line consists of the following processing modules. Each section outlines the module's function, operating principle, and available technical parameters.
1. Feeding System
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Electrode scrap is loaded onto the infeed conveyor and delivered to the crushing stage at a regulated feed rate. Consistent material feeding keeps the crusher operating within its designated torque range and prevents sudden overloads caused by dense bundles of stacked electrode sheets. |
| Parameter | Specification |
|---|---|
| Function | Meters electrode scrap into the crushing system at a controlled rate |
| Feed Material | Loose sheet, stacked laminate, roll ends, and trim |
| Discharge | Direct into crushing chamber |
| Configuration | Sized to line throughput and scrap format |
2. Crushing System
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The coarse crusher is a four-shaft shredder specifically designed for lithium-ion battery processing. Its enclosed box-shaped housing features four-fold sealing, allowing the crushing chamber to be filled with nitrogen to reduce oxygen levels around the cutting area and minimize ignition risks when processing charged cells. Batteries and modules are rapidly reduced into flake material. Microcomputer-based controls automatically manage startup, shutdown, reverse operation, and overload protection. The drive system operates at low speed with high torque, ensuring efficient size reduction with minimal noise. |
| Parameter | Specification |
|---|---|
| Function | Primary size reduction of electrode plates and laminate into flake material |
| Rotor Configuration | Four-shaft shredder |
| Chamber Sealing | Four-fold tightness, suitable for nitrogen filling |
| Atmosphere Control | Gas protection design available |
| 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 treatment |
3. Drying System
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Crushed material undergoes controlled drying at temperatures between 100 and 150°C. During this stage, organic compounds volatilize and are subsequently condensed for recovery. The operating temperature remains below the decomposition threshold of the film material, preserving its integrity for effective separation in the downstream processing stages. |
| Parameter | Specification |
|---|---|
| Function | Volatilization and recovery of organic matter from crushed material |
| Operating Temperature | 100 to 150 °C |
| Recovery Method | Condensation of volatilized organics |
| Film Condition | Film material 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 low-temperature pyrolysis at operating temperatures between 450 and 600°C. This process decomposes residual organic matter and impurities in the crushed battery material, including the polymer binder that bonds the electrode coating to the current collector foil. Removing these substances improves the purity of the black powder recovered during subsequent processing stages. |
| Parameter | Specification |
|---|---|
| Function | Thermal decomposition of binder, organic matter, and residual impurities |
| Furnace Temperature | 450 to 600 °C |
| Process Type | Low-temperature cracking |
| Target Material | Polymer binder and organic impurities in crushed electrode material |
| Process Benefit | Raises the quality of recovered electrode powder |
5. Exhaust Gas Treatment System
Exhaust gases generated during drying and cracking are processed through a three-stage treatment system. Catalytic combustion breaks down combustible organic compounds, followed by alkali washing and spraying to neutralize acidic and other harmful components. Activated carbon 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 hammer mechanism breaks down bulk material remaining after thermal treatment, preparing the processed stream for specific gravity separation of heavier components, including steel shells 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 for gravity sorting |
7. Fine Crusher
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The fine crusher completes the separation of electrode coating from the metal foil. Material remains inside the crushing chamber for an extended processing period instead of passing through immediately. Repeated mechanical action strips black powder from the pole pieces while converting copper and aluminum foils into granules. This granulation process creates the material characteristics needed for effective separation of copper and aluminum during the subsequent sorting stage. |
| Parameter | Specification |
|---|---|
| Function | Stripping of coating from electrode foil and granulation of current collectors |
| Residence Behavior | Extended retention in the crushing cavity |
| Output Form | Copper granules, aluminum granules, liberated electrode powder |
| Process Purpose | Enables clean copper and aluminum separation downstream |
8. Screening System
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The screening system uses multiple types of equipment selected according to the processing route, including linear screens, circular vibrating screens, swing screens, and airflow sorting screens. These machines combine static and dynamic screening methods to thoroughly separate black powder from the material through multiple stages rather than relying on a single screening pass. |
| Parameter | Specification |
|---|---|
| Function | Separation of electrode powder from granule and coarse fractions |
| Screen Types | Linear screen, circular vibrating 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 electrode powder |
9. Air Sorting System
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The air sorting system uses a controlled airflow to separate materials according to their weight and density. Lightweight particles are carried along by the airstream, while heavier particles resist the airflow and fall downward. This process separates film and other low-density residues from the metal granules. |
| 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 | Film material and low-density residue |
| Heavy Fraction | Copper and aluminum granules |
10. Gravity Sorting System
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Gravity separation performs the final metal sorting stage. First, residual black powder is screened out of the copper and aluminum granules. The remaining metal fractions then pass through a specific gravity sieving machine, which separates copper from aluminum based on their difference in 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. Central Control System
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Electrical systems throughout the entire processing line are managed by a Siemens PLC program. 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 connectivity options enable integration with the plant's DCS and provide the corresponding variable table. Electrical control cabinets feature 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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