From cells to materials: configuring a crushing and sorting line

Plan pre-treatment, crushing, sorting and supporting systems together.

Define the target fractions

Processing may target electrode powder, copper foil, aluminium foil, shell materials and separators. Feedstock and desired outputs determine the combination of pre-treatment and sorting stages.

Connect baking, crushing and sorting

The company materials describe low-temperature baking, staged crushing, screening, magnetic separation and density separation. Equipment selection considers material condition, target particle size and collection requirements.

Assess supporting systems at the same time

Condensation, gas collection and subsequent treatment form part of the line design. Equipment, energy use and downstream material handling vary with the selected route and need project-specific evaluation.

What each separation method contributes

Screening classifies particle sizes; magnetic separation exploits magnetic differences; air separation uses different motion in airflow; density separation further separates fractions by physical properties. Their combination yields powder, metal, casing and separator fractions, with routing also depending on particle size and liberation.

Plan solids, dust and off-gas separately

Solid separation, dust collection and process off-gas treatment serve solids, dust-laden air and process gases respectively, with their own collection and treatment requirements. Dust extraction handles dust-laden air at generating stations, while off-gas collection and treatment follow the thermal route. Condensation is a route-specific processing stage. Equipment order and interfaces follow the selected design.

Compare throughput, energy and recovery on matching bases

Throughput comparisons require chemistry, casing, liquid content and pre-treatment conditions. Distinguish installed power, actual electricity use and energy per tonne, stating whether auxiliary systems are included. Recovery calculations need a target fraction, input/output sampling and mass-balance basis; powder recovery is not recovery of all line inputs.

Connecting black mass to subsequent processing

Black mass is an intermediate material containing electrode active materials and other constituents. Define particle size, impurities, collection and downstream interfaces. Physical separation and subsequent refining have distinct output specifications and supply scopes.