Massive volumes of retired batteries are unlocking enormous circular economy potential. Industry data shows China’s cumulative retired power batteries are growing rapidly, with annual retirements projected to exceed one million tons by 2027. Nevertheless, conventional waste battery dismantling methods either rely on manual labor with low efficiency or adopt crude processes that cause environmental pollution. Most critically, the recovery rate of high-value materials remains unsatisfactorily low.

This represents not only resource waste but also a hidden environmental crisis.

Faced with a hundred-billion-yuan market and increasingly stringent environmental regulations, Puhler Circular has delivered a powerful solution via its self-developed intelligent dismantling production line for waste lithium batteries, redefining high efficiency and high purity in battery recycling.

Puhler Circular Power Battery Recycling Solution

01 Core Value: 98% Recovery Rate & Doubled Production Capacity

• Production capacity increased by at least 100%: 24-hour continuous, stable and fully automatic batch production with minimal frequent shutdowns for maintenance.

• Total recovery rate of metallic materials ≥ 98%: every gram of copper and aluminum is efficiently captured.

• Comprehensive black mass recovery rate ≥ 98.5%: nearly zero loss of cathode and anode powders to maximize material value.

• Impurity content of separated copper and aluminum controlled below 0.5%~1.0%. The yielded black mass can be directly adopted for hydrometallurgical regeneration with quality comparable to virgin raw materials.

In short, when processing the same batch of waste batteries, Puhler Circular’s production line extracts several tons more high-purity metals than traditional processes while slashing overall operating costs.

02 Process Flow: Five-Step Closed-Loop System Converting Waste into Raw Materials

The complete line consists of five core modules: Feeding & Electrically Charged Crushing, Drying Pyrolysis, Full-Component Physical Separation, Material Collection & Dust Removal, and Exhaust Gas Purification, forming a genuine closed-loop system that transforms waste batteries into reusable raw materials.

1. Feeding & Electrically Charged Crushing

   Featuring breakthrough electrically charged crushing technology, the line eliminates pre-discharge pretreatment and eradicates short-circuit risks at the source, delivering safer and more efficient feeding operation.

   

2. Drying and Pyrolysis

   Low-temperature oxygen-free pyrolysis thoroughly separates organic substances such as separators and electrolyte, laying a solid foundation for high-precision subsequent separation.

   

3. Full-component Physical Separation

   Multi-stage air classification, magnetic separation, eddy current separation and density sorting are adopted to accurately recover high-value components including black mass, copper, aluminum and separators.

   

4. Material Collection, Dust Removal & Exhaust Gas Purification

   The whole process adopts negative pressure closed design matched with pulse dust removal and activated carbon adsorption/catalytic combustion. The dust emission concentration is lower than 10 mg/Nm³, enabling standard-compliant exhaust discharge and eco-friendly production.

   

At present, the lithium battery recycling lines independently developed by Puhler Circular have been put into operation at multiple leading battery recycling enterprises, helping partners achieve sound economic and environmental benefits.