Leading the charge in Lithium-Ion battery recycling

At ANDRITZ, we are committed to sustainable solutions for the growing challenge of battery waste, driven by the expanding electric vehicle (EV) market. In collaboration with battery recycling pioneer Duesenfeld, we offer innovative processes, cutting-edge equipment, and comprehensive services for eco-friendly recycling. Together, we are transforming lithium-ion battery recycling and making a significant positive environmental impact.

The rapid adoption of EVs is a significant step towards reducing carbon emissions. However, it also presents the challenge of recycling the rare and valuable materials in lithium-ion batteries. Improper disposal of these batteries poses severe environmental risks, including soil and water contamination. With an expected exponential increase in end-of-life batteries and current production waste from gigafactories, responsible management is crucial. Additionally, new regulations worldwide heighten the importance of resource recovery, making it imperative for industries to adopt innovative and effective recycling solutions.

At ANDRITZ, we address these challenges with innovative processes and state-of-the-art equipment that optimize lithium-ion battery recycling, making a substantial positive environmental impact while ensuring economic competitiveness.

Our comprehensive battery recycling approach

ANDRITZ stands as a comprehensive front-end supplier in battery recycling, specializing in mechanical pre-treatment, commonly known as black mass production. This process includes several stages: discharging, shredding, drying, and finally sorting and separation.

The main output fractions from these processes are:

Black Mass: A mixture of graphite and valuable metals, including lithium, cobalt, nickel, and manganese from NMC batteries, and lithium, iron, and phosphate from LFP batteries. These metals are crucial for producing new batteries and electronic components, promoting sustainability and resource efficiency.
Copper and Aluminum Foils: Recovered from the anode (copper) and cathode (aluminum) electrodes. Recycling these metals reduces the environmental impact of mining and processing new materials, essential for manufacturing new batteries.
Heavy Parts: Structural components from the battery housing, such as steel, plastic, and cooper. Recycling these materials minimizes waste and allows for the reuse of valuable resources in new products.
Solvents and Electrolytes: Low-boiling solvents and electrolyte are recovered during the recycling process. Proper recovery prevents environmental contamination and allows these substances to be reused in industrial applications.
Separator Foil: Shredded and separated during the process. The separator foil can also be used as Refuse-Derived Fuel (RDF), providing an alternative energy source and reducing waste.

Main Output Fractions (left to right): Copper Foil, Aluminum Foil, Black Mass, Solvents, Heavy Parts, Separator Foil, [Source: Duesenfeld]

By partnering with Duesenfeld, a pioneer in environmentally friendly recycling of lithium-ion batteries, ANDRITZ offers battery recycling plants based on an eco-friendly and safe process. In combination with our cutting-edge equipment, we ensure high recovery rates while adhering to the highest environmental and regulatory compliance standards.

Key process features protected by Duesenfeld IP

Deep discharging

The Duesenfeld’s protected deep discharge process for lithium-ion batteries ensures safe and efficient energy recovery and handling during mechanical processing.

Their patented technology and intelligent control software automate discharging, regardless of the battery's state, voltage, age, or manufacturer. This results in high throughput and maximum efficiency, with recovered electricity powering part of the recycling plant or fed into the grid.

Key Features:

Maximum Safety: Continuous software monitoring guarantees safe operation and easy replacement of connected batteries.
No Electrical Risks: Patented technology eliminates electrical risks in subsequent steps, removing the need for high-voltage authorized personnel.
High Efficiency: Achieve large throughput and optimal energy recovery, ensuring process safety and employee protection.

Low-temperature thermal drying

The Duesenfeld protected low-temperature thermal drying process for lithium-ion batteries ensures efficient solvent recovery and minimizes environmental impact.

Operating below 80°C and under vacuum prevents the formation of hazardous hydrogen fluoride (HF) and eliminates the need for exhaust gas scrubbing and corrosion-resistant stainless-steel equipment. This process allows for the safe and effective drying of batteries, ensuring that solvents are efficiently recovered and reused.

Key Features:

Eco-Friendly: No toxic fluorine compounds are produced, reducing the need for high-grade equipment materials and gas scrubbing.
High Efficiency: Efficient evaporation of low-boiling solvents and recovery of pure electrolytes for reuse.
Cost-Effective: Lower operating costs due to the elimination of exhaust gas scrubbing and reduced CO2 emissions.

ANDRITZ & Duesenfeld: A perfect match in battery recycling

The partnership between ANDRITZ and Duesenfeld ensures we remain at the forefront of battery recycling technology, providing innovative, safe, and efficient solutions for a sustainable future.

Duesenfeld acts as a licensor of their patented processes, particularly in discharging and low-temperature thermal drying. They leverage extensive field test insights from their operating pilot plant and ongoing R&D work to optimize the recycling process and stay prepared for future changes in battery developments.

We as ANDRITZ, act as a solution provider (EPC/EPS), delivering a customized recycling plant according to all relevant standards including service offerings throughout the plant's lifetime. We manufacture key equipment within the process namely tailor-made shredder and drying equipment designed to meet specific process needs. Our proficiency in plant development and engineering, combined with a global presence through numerous subsidiaries and manufacturing sites, ensures comprehensive support and innovative solutions for battery recycling projects.

Benefits for our Customers:

Innovative Solutions: Cutting-edge technologies and processes for state-of-the-art recycling.
Comprehensive Expertise: Combined knowledge of two industry leaders for efficient recycling.
Customized Equipment: Tailor-made solutions for optimal performance.
Global Support: Consistent and reliable support worldwide.
Proven Process: Field-tested process for smooth and efficient operations.

Together, ANDRITZ and Duesenfeld form a perfect match in battery recycling. We drive innovation and excellence, delivering exceptional value to our customers. This partnership not only addresses current recycling challenges but also paves the way for future advancements in sustainable practices.

Standard Plant Layout of a lithium-ion recycling plant with a capacity of 2 t/h or approximately 13,750 t/a.

Key steps of the ANDRITZ-Duesenfeld mechanical pre-treatment plant

Discharging: The process begins with the controlled deep discharging of battery cells, modules, or packs and short circuiting, ensuring safety and energy recovery.
Shredding: Discharged batteries are either disassembled or directly fed into the ANDRITZ battery shredding tower, which includes a rotary shear pre-shredder and a granulator fine shredder. The system maintains an inert atmosphere using nitrogen to prevent fires or explosions, leveraging ANDRITZ's experience from fridge recycling.
Drying and Solvent Recovery: The shredded material is dried using the ANDRITZ dryer at temperatures below 80°C, efficiently evaporating low-boiling solvents. An integrated cooling system recovers these solvents, reducing environmental impact.
Off-Gas Treatment: The off-gas treatment system uses activated carbon filters to remove volatile organic compounds (VOCs) and other contaminants, ensuring compliance with environmental standards.
Separation and Sorting: The process involves multiple steps to separate heavy and light fractions, including black mass, electrode foils from aluminum and copper, and separator foils. This ensures high-quality output fractions.

This streamlined process ensures efficient and safe battery recycling, addressing environmental concerns and regulatory requirements.

Duesenfeld offers innovative recycling solutions for lithium-ion batteries, specializing in eco-friendly processes that ensure high recovery rates and minimal environmental impact. Their expertise spans across battery discharging, low-temperature thermal drying in mechanical pre-treatment and hydrometallurgical processing, providing comprehensive and efficient recycling processes.

Duesenfeld

Contact ANDRITZ

For your inquiry please use our contact form. The responsible department will contact you.

ANDRITZ AG

Recycling

+43 (316) 6902
recycling@andritz.com

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