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Recycling begins by sorting the batteries into chemistries. Collection centers place lead acid, nickel-cadmium, nickel-metal-hydride and lithium‑ion into designated drums, sacks or boxes. Battery recyclers claim that if a steady stream of batteries, sorted by chemistry, were available at no charge, recycling would be profitable.
The recycling process generally begins by removing the combustible material, such as plastics and insulation, with a gas-fired thermal oxidizer. The plant’s scrubber eliminates the polluting particles created by a burning process before releasing them into the atmosphere. This leaves the clean and naked cells with their valuable metal content. The cells are then chopped into small pieces and heated until the metal liquefies. Non-metallic substances are burned off; leaving a black slag on top that a slag arm removes. The alloys settle according to weight and are skimmed off like cream from raw milk while in liquid form.
Cadmium is relatively light and vaporizes at high temperatures. In a process that appears like a pan of water boiling over, a fan blows the cadmium vapor into a large tube cooled with water mist, and the vapors condense to produce cadmium that is 99.95 percent pure.
Some recyclers do not separate the metals on site but pour the liquid metals directly into what the industry refers to as "pigs" (65 pounds, 24kg) or "hogs" (2, 000 pounds, 746kg). Other battery recyclers use the 7-pound nuggets (3. 17kg). The pigs, hogs and nuggets are then shipped to metal recovery plants where they are used to produce nickel, chromium and iron for stainless steel and other high-end products.
Toxco uses liquid nitrogen to freeze lithium-based batteries before shredding, crushing and removal of the lithium, as well as other battery components. The lithium is dissolved in a solution to make the metal non-reactive and is sold for producing lubricating greases. Similarly, the cobalt is separated, collected and sold.
Battery recycling is energy-intensive, and it takes 6 to 10 times more energy to reclaim metals from recycled batteries as it does to produce the materials through other means, including mining. Let’s explore who pays for the recycling of batteries.