Mechanical and physical processes of battery recycling

The rising production of lithium-ion batteries (LIBs) due to the introduction of stationary and portable energy-storage devices as well as electric mobility in particular demands an efficient and sustainable waste management scheme. In principle, the material transformation from end-of-life (EOL) LIBs to secondary (raw) materials follows the recycling chain for wastes. Therein, processing aims to break up the bonds between the individual components and materials of the battery to enrich them into defined concentrates for subsequent metallurgical refining. In general, mechanical processes are more energyefficient and economically affordable than thermal, chemical, and metallurgical ones. Consequently, a combination of several crushing, size classifying, and sorting steps are commonly used to prepare concentrates for further treatment. This chapter presents the principles of mechanical liberation and physical separation processes for EOL LIB processing. Combinations of specific processes categorized by their feed materials are proposed and discussed, outlining possible material fractions and further potential for research and development. LIB recycling with a mechanical processing unit is shown to achieve high recycling efficiencies that enable the fulfill the upcoming and updated European legal framework regarding LIB disposal.