In our previous article, we explored the different types of batteries which can be sent to EWaste Africa for safe and responsible end-of-life management. Now we would like to share what happens next and how these batteries are recycled or refurbished in a way that’s both environmentally friendly and legally compliant.
From a circular economy point of view, the best solution for end-of-life batteries is refurbishment. This means giving batteries a second life by repurposing them for use in less demanding applications. For example, cells from electric vehicles can be used to create home battery energy storage systems (BESS). Even if these batteries are no longer suitable for high-performance use, they can, in many cases, still function reliably for household energy requirements where there is not the same level of performance demand. Many batteries that are considered end-of-life by industrial standards can still be successfully used for many years in the right conditions.
However, not all batteries can be refurbished. Some are damaged or too degraded even for less demanding applications and need to be recycled instead. Recycling ensures that no harmful chemicals leak into the air, soil or water, protecting both human health and the environment. It also allows the recovery of many valuable materials such as cobalt, nickel, copper and aluminium, which can be used in the manufacturing of new cells.
Refurbishment and recovery of materials from waste is one of the best methods of reducing carbon footprint, which can help us get closer to a carbon-neutral economy (where the amount of carbon dioxide and other greenhouse gases emitted is equal to the amount that is being removed). In addition, the reduction in the demand for virgin materials also protects the environment by reducing the requirements for primary production facilities (such as mining, forestry, etc.).
To effectively and efficiently recycle a battery, several key steps must be undertaken. First, the battery must be deactivated or discharged to improve safety during handling. Our R&D team recently published a review article in the Battery Energy Journal on chemical methods for battery deactivation. Next, the battery must be disassembled into the individual cells to enable the subsequent recycling or refurbishment processes. The battery casings are separated from the cells at this point and can be recycled.
In the next step, the cells undergo mechanical recycling, where the cells are shredded to break them down into smaller pieces and extract the components from within the cells. The shredded cells are separated into different materials such as steel, aluminium, copper, plastics, electrolyte solution (the liquid or gel allowing the flow of electricity) and black mass (a fine dark powder rich in lithium, nickel, cobalt, and graphite). The term “black mass” is due to the dark appearance of graphite, a carbon form commonly used as an anode material in batteries.
Once the materials are separated, they are subjected to chemical and physical processes, such as pyrometallurgy and hydrometallurgy, to extract valuable metals for reuse. While the basic recycling steps are similar across battery types, some variations exist depending on the chemistry. For example, lead-acid batteries contain both sulfuric acid and lead. The acid must be neutralised with a base like sodium hydroxide, and the lead must be carefully handled due to its toxicity, particularly its long-term effects on the nervous system.
At EWaste Africa, we are committed to offering an environmentally responsible and legally compliant solution for battery disposal. If you have used batteries that need proper management, we invite you to make use of one of our collection containers available throughout South Africa or to contact us directly. Together, we can keep harmful substances out of the environment and recover valuable materials that support a sustainable future.
