Batteries power our modern lives, from portable electronics to electric vehicles. As battery usage surges, responsible end-of-life management through recycling becomes crucial. While we often hear about lithium-ion battery recycling due to the electric vehicle boom, and personal devices, older nickel-based battery technologies also need to be recycled, and do not belong in the waste stream. It is important to note that the processes and challenges involved in demanufacturing these batteries differ significantly.

Understanding the Batteries

Nickel-Based Batteries

These are common, especially in the form of rechargeable AA and AAA batteries, often replacing single-use alkaline batteries. These are commonly found in consumer electronics, some power tools, and some medical devices. They are also found in Hybrid Electric Vehicles (HEVs): Many established hybrid cars still use NiMH battery packs due to their proven reliability, safety record, and cost-effectiveness, although newer models increasingly use Li-ion.

Lithium-ion Batteries

The current dominant technology for smartphones, laptops, some medical devices, fully Electric Vehicles (EVs), and grid storage. They offer higher energy density.

Nickel Battery Recycling: A Mature Process

Recycling processes for Nickle batteries are relatively well-established, often utilizing pyrometallurgical (heat-based) or hydrometallurgical (chemical-based) methods.

• Collection & Sorting: This is seen in many instances as part of the demanufacturing process in which devices are broken down and the materials are separated whenever possible. Nickle based batteries are collected and sorted by chemistry.


• Processing (Often Pyrometallurgy):
  
  
  
  • Batteries (often without extensive dismantling, though plastics might be removed) are fed into high-temperature furnaces (smelting).
  
  
  • The heat burns off plastics and electrolytes.
  
  
  • The metals melt and separate. Primarily, an Iron-Nickel alloy is recovered.
  
  
  • Crucially for recycling process: One of the elements in Nickel batteries, Cadmium, is volatile and vaporizes at smelting temperatures. Specialized off-gas collection and condensation systems are essential to capture the toxic Cadmium for reuse or safe disposal.
  
  
  • Slag containing other elements is also produced and must be handled properly.
  
  
  
  


• Material Recovery: The primary outputs of Nickel Batter recycling are Nickel, Iron (often recovered together as ferronickel or nickel-iron), and, in some cases high-purity Cadmium. These materials can then be refined and reintroduced into manufacturing, often back into batteries or stainless-steel production. Hydrometallurgical processes can also be used, dissolving metals selectively using acids. Today, 68% of all nickels are recycled using demanufacturing and recycling processes.

Lithium-ion Battery Recycling: A Complex and Evolving Field

As we have discussed in our previous article on recycling Lithium Batteries, recycling these batteries face more significant hurdles due to several factors:

• Safety: Li-ion batteries store considerable energy even when "discharged" and contain flammable electrolytes. Mishandling during collection, transport, or dismantling can lead to fires or explosions. Discharge and careful handling are paramount.


• Complexity & Variety: Numerous lithium-ion battery chemistries exist, each with slightly different material compositions. The intricate layered structure (thin foils coated with active materials) makes separation challenging.


• Material Value & Recovery Targets: While Nickel and Cobalt in Nickle batteries are valuable, Lithium recovery has historically been less efficient or economical, though this is rapidly changing due to increasing lithium demand and prices. Graphite recovery is also an area of development.


• Processing Methods:
  
  
  
  • Pyrometallurgy: Similar to nickel batteries, smelting recovers bulk metals like Nickel, Cobalt, and Copper into an alloy. However, Lithium, Aluminum, and Graphite are typically lost to the slag or off-gas, requiring separate, often complex, recovery steps if desired. This process destroys the complex cathode structure.
  
  
  • Hydrometallurgy: Often follows shredding or pyrometallurgy. Shredded battery material ("black mass") is treated with acids to leach out valuable metals (Li, Co, Ni, Mn). These are then selectively precipitated or extracted as chemical salts for reuse, often in new battery cathodes. This method can achieve high recovery rates but involves chemical reagents.
  
  
  
  

The Bottom Line

Batteries power our connected world, but their lifecycle does not end when they stop holding a charge. By choosing to recycle, we actively participate in protecting our environment, conserving valuable resources, strengthening our economy, and enhancing public safety. It is a small action with a powerful, positive impact on our sustainable future. Do not trash that battery – it still is valuable.

Do you need help?

Do you need assistance with Battery recycling solutions to help you to track your diversion and contribute to the Circular Economy? Genesis Dome can assist; our unique management processes can support you in ensuring that materials, including those precious materials found in Batteries. With our unique processes we can support you by diverting up to 98% of your materials from the landfill. We can also provide guidance and solutions to solve recycling challenges. Please contact us!