Processing Track: Mineral Processing, Refining and Recycling · Module 3 of 4 · about 15 min
Battery recycling
Lithium-ion batteries hold lithium, nickel, cobalt, manganese, copper and aluminum. Recycling them keeps those metals in use and keeps damaged batteries out of the trash, where they can start fires. EPA warns that lithium-ion batteries should not go in household trash or regular recycling bins.
A typical line starts by discharging and dismantling packs, then shredding cells under controlled conditions. Shredding produces metal scrap and plastic plus black mass, a dark powder that holds most of the valuable cathode metals.
Black mass is refined in one of two main ways. Pyrometallurgy smelts it at high temperature, which is robust but loses some metals such as lithium to slag. Hydrometallurgy leaches it in acid and separates the metals chemically, which can recover lithium but needs careful chemical handling. Direct recycling, still being developed at the DOE ReCell Center, tries to restore cathode material without breaking it down fully.
The safety side is fire. Damaged or charged cells can go into thermal runaway, where heat drives more heat and the cell vents flammable gas. Recycling plants store batteries in separated, monitored areas, discharge them before processing and train crews on battery fire response.
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Module quiz
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