Fossil fuels are to be gradually replaced by other energy sources. The production of accumulators and batteries as storage media for regenerative energies is increasing. As a result, the need for economical recycling methods is also increasing. In addition, the climate debate, increased environmental awareness, high gasoline prices and emissions scandals are making e-cars more and more popular - but what to do when the raw materials for the production of e-car batteries run out? And where to put the spent batteries afterwards?
BHS-Sonthofen offers an efficient and safe process with which rechargeable batteries and batteries can be recycled in an environmentally friendly and safe manner - and valuable raw materials such as copper, lithium, nickel, cobalt or manganese can be returned to the value cycle.
BHS-Sonthofen launched several research projects to develop an innovative and safe process for the environmentally sound recycling of batteries and accumulators. The new recycling process delivers two distinct advantages: Not only are the valuable minerals prevented from ending up as electronic waste, but the process also helps to counter the impending shortage of raw materials and rare earths. An innovative method is at the heart of the recycling process, which takes place in a protective atmosphere that extends from the crusher all the way to the dryer, where the electrolytes are vaporized. This is how BHS avoids the main hazards of recycling batteries: fires and toxic gases.
Recycling spent batteries and accumulators is not an easy task. If they end up in the wrong shredder, this can lead to dangerous fires. The innovative process from BHS-Sonthofen deliberately avoids this danger. After the batteries have been discharged, they are shredded under a protective atmosphere using either one or two shredding machines. The BHS rotary shear of type VR handles the pre-shredding process. This slow-speed twin-shaft crusher crushes bulky battery packs and modules reliably with its interlocking blades. The cells or pre-crushed fraction is brought to the target size in a single-shaft crusher, such as the universal shredder of type NGU, during the main crushing step.
Once the feed material has reached the desired target size, the parts fall through appropriately designed grid segments in the universal shredder (NGU). The crushed batteries are then heated in batches in horizontal batch or continuous dryers of type AVA HTC-T and AVA HTK-T to evaporate the electrolyte components for subsequent recovery in a condensation unit. Dry mechanical processing is used to render the solid components completely free of electrolytes. Black mass can be recovered as soon as initial screening has been performed. Light and heavy materials are then sifted and separated. The remaining composites are sent for a second phase of shredding and are then fed into a dry mechanical sorting system. The black mass, smelter-grade copper concentrate and concentrated aluminum are recovered as end products.
Our shredding machines are available in different sizes to meet your individual requirements. Our systems allow you to process any type of cell and module. The end products are aluminum, high-grade copper concentrates and pure black mass, which contains lithium salts, manganese, cobalt or nickel depending on the type of battery. All three fractions are immediately ready for remarketing.