Battery recycling solutions

The feed preparation process begins by determining whether battery modules require dismantling into constituent cells. This step ensures safe handling and processing of the batteries. Modules may also need to be discharged to a specified level to limit power before shredding, depending on their format and state of charge upon arrival.

The shredding and beneficiation stage processes spent batteries of various sizes, formats, and chemistries, including lithium cobalt oxide (LCO) cathodes from consumer electronics and nickel-rich lithium-nickel-manganese-cobalt (NMC) cathodes from electric vehicles and stationary storage applications. During shredding, plastic and metal components are separated from the "black mass," which contains the active materials of the battery.

The wet shredding process allows for the safe handling of partially discharged batteries. Multiple safety systems, including an inert gas environment, are used to manage fire risk during shredding. After shredding, drying and beneficiation further separate coarse plastic and metal materials from the feed. These recovered materials can be utilized in two ways: they may be sold as scrap to existing metal and plastic recyclers, providing an additional revenue stream, or they can be reintegrated into the customer's own battery supply chain, closing the loop and enhancing sustainability efforts.

The black mass produced in Stage 1 contains critical active materials such as lithium, nickel, and cobalt. These materials can be refined through hydrometallurgical processing in a separate plant. The refined chemicals are of high purity and suitable for reuse in battery cathodes.

The second recycling stage processes black mass, which contains the active materials recovered during shredding and beneficiation. In the leach circuit, metals such as cobalt, nickel, manganese, copper, and lithium are extracted from the black mass. The pregnant leach solution (PLS) is separated from the solid leach residue, enabling further purification and recovery of valuable materials.

Cobalt and nickel are recovered as high-purity sulphates, which can be reintegrated directly into the lithium-ion battery supply chain for cathode manufacturing. Lithium is recovered as lithium sulphate, which can be converted into lithium hydroxide or lithium carbonate, both of which are essential for battery production.

The process also yields manganese and copper sulphates, which are suitable for sale to existing refineries or for direct industrial applications. The solid leach residue contains graphite anode material, which is dried and drummed for sale, offering customers flexibility in how they utilize recovered materials. The final product from Stage 2 is a liquid ammonium sulphate solution, which is concentrated and crystallized for sale into the fertilizer market.

Primobius enables customers to achieve high recovery rates for critical materials, supporting the circular economy and reducing reliance on mined resources. The hydrometallurgical process operates at low temperatures, minimizing energy consumption and emissions while delivering high-purity products that meet the demands of modern industries.