BHS-Sonthofen publishes whitepaper on recycling lithium-ion batteries

November 15, 2022
The whitepaper addresses various methods for safely processing lithium-ion batteries and the challenges associated with these new technologies. In it, BHS also presents its own new, innovative process that recovers valuable resources such as nickel, cobalt, lithium and copper from batteries and rechargeable batteries. The whitepaper is available to download free of charge on the BHS website.

The growing demand for electric cars and other battery-powered vehicles has seen the recycling of LIBs receive more and more attention. The new whitepaper from BHS-Sonthofen addresses the economic, process, safety and environmental challenges associated with recycling LIBs. It provides more detailed explanations on the various methods available to process them safely and efficiently  – including calcination, pyrometallurgical and mechanical dry and wet processes. One focus is on the new approach to the mechanical dry process BHS-Sonthofen.

Mechanical dry process for recycling LIBs from BHS-Sonthofen

It is estimated that about 20 percent of road vehicles will be running on battery power by 2025. This increases the need for effective recycling solutions for used batteries in order to continue using valuable and limited resources such as lithium, nickel and manganese. To this end, BHS-Sonthofen has developed a three-stage process that aims to create a high recovery rate for the resources contained in them.

The mechanical dry process consists of three main stages: Shredding, drying and gas cleaning. Depending on its size, the input material is shredded in one or two steps, evenly distributed in a homogenizer and then gently heated in a dryer. A gas treatment system cleans the flue gas flow. The result is a cleaned mixed fraction for which BHS also offers sorting using screening, air and magnetic separation technology.

Testing with customer material allows the process to be customized

In light of the rapid progress being made in modern electromobility, the process experts at BHS-Sonthofen are continuously developing the mechanical dry process further so as to be able to quickly offer solutions for new battery types as well. Customers also have the opportunity to test the efficiency of the process on their own material in advance at the company’s own Test Center in Sonthofen, Germany. A customized recycling approach is then created based on the results, which includes a profitability analysis.