LIB traction batteries made of high-performance lithium-ion cells, form the basis of modern energy supply. Solar energy, hydro and wind power, geothermal energy, e-mobility, artificial intelligence, communications and many more technologies will in the future be based on lithium storage systems.

‘Our core technologies in battery recycling are able to treat those hazardous materials without leaving any residues,’ say Rui Barradas, CEO of Barradas and Claas Reckelberg, CEO of RET . ‘Ultimately, we help recyclers extract valuable raw materials with the highest degree of purity.’

Battery recyclers are no exception. Thanks to the developed process technology, battery ingredients such as cobalt, lithium, nickel and copper can be refined and recovered extremely efficiently while reducing energy costs.

‘Through the LIB recycling process designed by us and equipped with our components, all chemistries including NCA, NMC, LFP, LCO and LMO can go back into the loop,’ the partners point out.

Cells of all housing materials, such as aluminium, steel, plastic or pouch as well as various housing formats, are suitable for its technologies – with almost no size limitation.

‘Providing customised solutions according to the specifications and wishes of our customers is our top priority,’ the entrepreneur says. ‘That’s why we offer a wide range of options and focus on realising individual concepts.’

The partners have defined three stages in the LIB process:

• Step 1: LIB must be electrically discharged before further recycling to ensure operational and process safety as well as optimal product quality. All versions of RET discharge are based on the latest and safest high-voltage discharge technology for LIB storage and modules.

The discharge capacity of the system is freely definable by the number of channels installed and their capacity at different voltage levels. In installations with many channels, each individual channel can be operated completely independently of all others.

Due to the bi-directional design, power can be converted with high efficiency from the batteries to the local net and vice versa. The power taken from the batteries thus has the effect of directly reducing consumption. All parameters of the discharge can be clearly adjusted on the touchscreen based control.

The operator can create parametric recipes for the discharge and diagnostics of different battery systems and save the recorded log data. The discharge systems are designed for seamless integration into incoming testing and disassembly of battery systems.

• Step 2: Batteries must be dried after discharge to separate the combustible Team Barradas and RET electrolyte. LIB to be processed are inserted via a sluice system and fed to the upstream BRS 4CUT, which ensures optimum particle size. The BRS 4CUT is designed for the size reduction of various input materials.

The size of the output material is determined by means of a quick change screen basket. The machine is designed for highest torques and maximum throughput rates. Due to its particularly robust design, the machine is not susceptible to breakdown.

The intelligent Barradas ICS control system permanently monitors the machine parameters and always ensures optimum shredding results through automatic adjustment. The RET vacuum dryers are double walled horizontal paddle dryers in which the volatile organic battery electrolyte is evaporated.

The powerful vacuum system allows drying to take place at particularly low temperatures. Based on the process parameters, the system automatically sets the necessary residence time while achieving ideal drying results and low inert gas consumption.

The evaporated electrolytes are condensed out by multi-stage heat exchangers and filled in liquid form. The downstream exhaust air purification system already exceeds the future emission limits required by the EU.

• Step 3: The final step of battery recycling is the mechanical separation of the crushed and dried materials. Here we have the latest generation of a proven technology. The RET impact reactor, which is protected, is a robust and low-maintenance unit for the shredding and simultaneous separation of the available raw materials by type.

The impact reactor is a high-speed crusher with a vertical drive system and fixed impact elements at the bottom of the impact chamber. Utilising the impact energy of the incoming materials against each other and against the highly wear-resistant lining on the side, maximum de-coating of black mass from the electrode foils and housing parts is achieved.

The coarse material (electrode foils and housing elements), which has been cleaned from the black mass is mostly ball shaped and discharged via the discharge flap for further separation Due to the high centrifugal forces and the created air flow inside the impact chamber, in combination with the proprietary deflector wheel technology, the impact reactor is suitable to efficiently separate the exposed, dusting black mass.

Together with the extended exhaust filter system, it serves as the sole recovery point for black mass. Further sorting of aluminium, copper and plastic is realised on a customerspecific basis using various techniques, such as sieving, zigzag sifters, eddy current separators and separating tables.

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