BCA forms LithiBatt to provide battery recycling systems

BCA Industries, an original equipment manufacturer based in Milwaukee that provides turnkey, closed-loop recycling systems, says it has formed the LithiBatt division to provide lithium-ion (Li-ion) and lithium-iron-phosphate (LiFePO4) battery recycling systems in collaboration with leading global partners.

The turnkey systems offer various processing outcomes that include options for progressively smaller sizes of material shredding, as well as additional processing steps to generate higher value, battery-grade precursor cathode active material (pCAM) and black mass that contains high amounts of graphite, lithium, manganese, cobalt and nickel metals, according to BCA. These systems also are designed to address the extraordinary safety requirements and proper volatile organic compounds extraction needed when processing these batteries.

“With primary, secondary and downstream equipment, Li-ion batteries of all sizes and chemistries can be quickly and profitably reduced into valuable, reusable or saleable materials without disassembly,” says John Neuens, industrial consultant for LithiBatt. “This type of flexible system can recycle tons of Li-ion material per hour to whatever sellable state the customer requires.”

BCA says LithiBatt is installing several systems (See a virtual tour here.) in Germany and the U.S. and is building systems for an EV manufacturer.

Additionally, LithiBatt is partnering with Green Li-ion, a lithium-ion battery recycling technology company with locations in the U.S., Europe, Australia and Singapore. Green Li-ion has developed a novel technology that processes all the valuable elements present in black mass. The technology and process enable the recycling of all metals to directly remanufacture battery-grade cathode material ready for reuse in new batteries, BCA says.

To accelerate Li-ion battery recycling market growth, LithiBatt has applied for a U.S. Department of Energy (DOE) grant to build a demonstration facility that allows manufacturers and recyclers to see the process in action, obtain test data and fully understand what they are purchasing.