Battery recycling: what equipment is needed to effectively process black mass?

Choosing a processing system for black mass is strategic in the battery recycling industry. This black powder, resulting from the dismantling of lithium-ion cells, contains critical metals such as cobalt, lithium, or nickel, and represents a high-value resource. However, its handling poses major challenges: safety, ATEX, containment, precise dosing, automation… In this article, we explore the best technical solutions for managing black mass at each stage of the process: from transfer to final packaging. A comprehensive guide for engineers, production managers, or industrial project leaders.

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1.1 Understanding what black mass is and why it is essential

In the context of lithium-ion battery recycling, black mass refers to the powder mixture resulting from the dismantling and mechanical processing of cells. This black residue contains high-value critical materials, such as lithium, cobalt, nickel, and manganese. For recycling industrialists, black mass represents both a major economic opportunity and a considerable technical challenge. Its processing determines the quality of metal recovery, the profitability of the process, and compliance with environmental and health standards. Understanding it, therefore, lays the foundation for informed decisions on handling, containment, and valorization solutions.

1.2 Controlled processing from the very first stages of the process line

At Palamatic Process, we intervene precisely in the critical phases of black mass processing: from its exit from grinding to packaging or transfer to chemical refining stages. Thanks to our experience in handling fine, toxic, or abrasive powders, we design secure and customizable lines:

• Dense phase pneumatic transfer stations: for displacement without dispersion or segregation of metallic powders.
• Reinforced containment equipment (glove box, integrated dust collection, ATEX filtration).
• Solutions for sieving, weigh dosing, and big bag filling perfectly adapted to the fine and volatile nature of black mass.
• Complete automation possible via our Pal'Touch® interface.

By adapting each piece of equipment to the specific behavior of black mass (abrasiveness, hygroscopicity, variable particle size), we guarantee a fluid, safe process compliant with regulatory requirements (ATEX, REACH…).

1.3 What is the black mass from battery recycling?

Black mass is a mixture of metallic powders obtained after end-of-life and grinding of lithium-ion batteries. It contains strategic elements such as lithium, cobalt, manganese, and nickel. Its processing allows these rare metals to be recovered and reintroduced into new production cycles. Due to its chemical complexity and volatile nature, it requires specific handling equipment, often in a confined or ATEX environment.

2.1 Anticipating risks related to black mass manipulation

Handling black mass is not something to be improvised. Its fine particle size, conductive metal content, and potentially explosive or moisture-reactive behavior impose very strict technical requirements. Added to this are human safety, environmental protection, and regulatory compliance challenges. Engineers and production managers this material must integrate from the design phase:

• Hermetic containment devices,
• Mastery of ATEX risk,
• Management of volatile metallic dusts,
• And robust equipment resistant to abrasion and corrosion.

2.2 Custom-designed lines for safety and production continuity

Palamatic Process designs process lines specifically adapted to black mass treatment, considering the following critical parameters:

1. Containment and Filtration

Stations equipped with glove boxes, introduction airlocks, dust collection rings, or suction hoods. Integrated dust collection with ATEX filter cartridges or connection to a centralized network.

2. ATEX Compatibility

All our equipment can be certified for ATEX zones 20/21, with grounding connections, anti-discharge components, and secure interfaces. Automated grounding solutions and verification by integrated sensors.

3. Product Behavior: Abrasion, Hygroscopicity

Use of specific steels (316L stainless steel, anti-abrasion steel). Electropolished or mirror-polished finishes to limit product adhesion. Adaptation of inflatable seals and sleeves to the necessary chemical resistance.

4. Cleaning and Maintenance

Quick disassembly (Easyclean), hygienic design, and CIP/SIP options for critical equipment. Limitation of retention zones to avoid cross-contamination.

These devices allow for maintaining a high level of productivity while ensuring operator safety and product integrity.

2.3 Does black mass processing require ATEX equipment?

Yes. Due to the content of fine and conductive metallic powders (such as cobalt or nickel), black mass is considered a product with a high risk of dust explosion. Transfer, dosing, or packaging equipment must therefore be designed according to ATEX standards (zones 20, 21, or 22 depending on the case). This includes grounding, certified motors, antistatic seals, and active monitoring of pressure or temperature.

3.1 Structuring a complete, flexible line adapted to recycling constraints

In the battery recycling industry, each site has its own constraints: volume of black mass processed, desired degree of automation, available space, regulatory requirements… Designing a high-performance processing line is not just about assembling equipment. One must think in terms of global flow, automation, modularity, and scalability. For industrial managers, the challenge is to obtain an installation that is:

• Effective from its commissioning,
• Easy to scale up in case of capacity increase,
• And integrated into an existing production environment.

3.2 A modular and automated approach with Palamatic technologies

Palamatic Process develops turnkey or integrated process lines into existing systems. The automation of the black mass processing line is based on a modular architecture controlled by our Pal’Touch® interface, which guarantees:

1. Complete or partial cycle automation

• Automatic unloading of containers (big bags or sacks) with confined discharge stations.
• Pneumatic transfer to sieves or buffer hoppers, with real-time supervision.
• Weigh dosing or volumetric dosing with traceability management.
• Automated filling of containers (big bags, drums, sacks...) with sealing or lining options.

2. Supervision and Traceability

Pal’Touch® offers precise batch tracking, production history, quality reports, and allows integration with an ERP.

3. Modularity and Scalability

Each module (unloading, transfer, sieving, dosing, packaging) can be sized according to initial needs. It is possible to duplicate a station, add an additional dosing station, or integrate a sieving or grinding stage as the process evolves. This modular design allows for reducing initial investments while preparing the plant for an increase in power or an expansion of the types of materials processed (rare earths, oxides, hydrometallurgy...).

3.3 Can black mass processing be fully automated?

Yes, it is entirely possible to automate the black mass processing line, from material reception to final packaging. Thanks to equipment integrating containment, dosing, transfer, and quality control, the entire cycle can be managed automatically via a centralized interface. This automation helps secure operations, guarantee consistent yields, and meet the traceability requirements imposed by strategic industries.

4.1 Mastering black mass packaging in a sensitive environment

Once the black mass is processed and prepared, it must be packaged for temporary storage or shipment to chemical refining units. However, this step is critical for three reasons:

• The material is toxic and potentially reactive,
• The volume of powder can generate significant dust emissions,
• Packaging often involves requirements for commercial weighing, hygiene, and traceability.

Any deviation at this stage can lead to material losses, non-compliance with regulatory thresholds, or even health risks for operators.

4.2 Filling stations adapted to black mass

Palamatic Process offers powder packaging solutions adapted to the constraints of black mass, with a high level of safety, containment, and precision:

1. FlowMatic® Big Bag Filling

ATEX-compatible stations, with inflatable sealing joint, net or gross weighing. Options for vibrating tables for powder compaction. Automatic hooks for contactless release. Possibility of internal bag sealer or external lining for storage in a controlled atmosphere.

2. Fine Bagging or Drum Packaging

PalSack® fillers, semi-automatic or automatic, integrating a screw weigh feeder for < 1% precision. Possible integration of dust collection rings, suction hood, or glove box for sensitive areas. Closure by automatic sealing or sewing, with integration of traceability printers.

3. Weighing and Traceability

Legal metrology systems for material trade, with automatic final weight verification. Automatic generation of batch labels, ERP compatibility.

4.3 What is the best packaging for black mass?

The packaging of black mass depends on the end customer's constraints and associated logistics. In general, the big bag remains the most suitable for volume and cost reasons, provided an effective containment system is integrated (inflatable seal, suction, lining). For finer quantities or sensitive applications (cleanrooms, chemistry), drum packaging with a welded internal bag is preferred. In all cases, precise weighing and batch traceability are essential.

5.1 Drawing inspiration from concrete achievements to validate project feasibility

Faced with the constraints of black mass processing, industrial managers need concrete references to confirm the reliability of the proposed technologies. Based on real projects, it is easier to understand how different technical components (transfer, dosing, containment, packaging) can be integrated into an existing environment. It is also a way to visualize the adaptation flexibility of Palamatic solutions when dealing with products with complex behavior, particularly in the context of battery recycling or critical powder processing.

5.2 Examples of installations for black mass and rare earths

Customer Case 1 – Confined transfer of black mass to a weigh dosing station (Northern Europe)

Customer problem: reception of ground black mass in drums, secure transfer to a hydrometallurgical refining line.

Implemented solution:

• DrumFlow® drum unloading station with localized suction.
• Vacuum dense phase pneumatic transfer (VFlow®) to a buffer cyclone.
• Online screw weigh dosing with automated flow control.

Result: 30% reduction in environmental dust levels, continuous process, integrated weighing.

Customer Case 2 – Automatic black mass packaging line in big bags (France)

Customer problem: packaging of black mass post-chemical treatment, high throughput, compliance with ATEX standards.

Implemented solution:

• FlowMatic® 06 station, high-throughput big bag filling (30–60 big bags/hr).
• Net weighing, electric hoist, inflatable seal.
• Automatic lining and motorized outfeed conveyor.

Result: throughput achieved with a single operator, dust exposure divided by 10.

Customer Case 3 – Preparation and transfer of rare earths post-drying (Southeast Asia)

Customer problem: transfer of very fine and abrasive rare earths (cerium oxide, lanthanum), with a requirement for total containment.

Implemented solution:

• Buffer hopper with flat-bottom discharger, electropolished finish.
• Pressure dense phase pneumatic transfer, hermetic connection.
• Glove boxes in the filling area.

Result: 100% containment, no clogging, simplified cleaning between batches.

5.3 Can an existing line be adapted for black mass processing?

Yes. It is entirely possible to adapt an existing production line for black mass processing, provided its compatibility with ATEX standards and containment requirements is verified. Palamatic Process offers on-site technical audits to assess the necessary modifications (strengthening seals, integrating weighing modules, optimizing pneumatic transfer…). A line initially designed for food or chemical powders can thus be converted to handle strategic materials like black mass.

Black mass is much more than just a residue from battery recycling: it is a strategic material, rich in critical metals, at the heart of the energy transition. But its handling requires rigor, safety, and technical expertise. As a recognized specialist in handling sensitive powders and complex process lines, Palamatic Process offers reliable, scalable solutions perfectly adapted to the challenges of black mass processing. Whether for transfer, dosing, containment, or packaging, we support each client with a custom approach, compliant with the most demanding standards.

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