Li-ion Battery Recycling Plant Feasibility Study

SCM excels in providing comprehensive turnkey solution (PMC) for lithium-ion battery recycling, ensuring efficient processes from beginning to end. Equip your business with critical insights and detailed analysis before making your strategic decisions.

Purchase

Feasibility Study: Establishing a Lithium-Ion Battery Recycling Plant
With the electric vehicle market continuing to grow, the demand for lithium-ion batteries is on the rise. This study examines the feasibility of setting up a lithium-ion battery recycling plant in India, focusing on addressing environmental challenges and taking advantage of the booming e-mobility sector.

Battery Chemistry & Design:

Detailed Breakdown: Understand the structure of lithium-ion batteries, including the roles of the anode, cathode, electrolyte, and more.
Design Features: Explore key design elements like separators, current collectors, casing, temperature regulation, and voltage control that contribute to battery performance and safety.
Advanced Chemistries: Learn about different battery types—such as Lithium Iron Phosphate (LFP), Nickel Manganese Cobalt (NMC), and emerging solid-state technologies—each with unique strengths and applications.

Composition & Materials:

Component Analysis: Delve into the materials used in lithium-ion batteries, from graphite and lithium salts to copper and aluminum collectors. Learn how the composition impacts energy storage, cost, and safety.
Emerging Trends: Discover innovations in cathode materials that offer improvements in energy density, safety, and longevity, especially for applications in EVs and renewable energy.

The Growing Need for Recycling:

Resource Conservation: Understand the critical role of recycling in conserving essential materials like lithium, cobalt, and nickel, reducing dependence on mining and lowering environmental impact.
Environmental Protection: Learn how proper recycling prevents hazardous waste, reduces carbon emissions, and complies with global environmental regulations.
Energy Conservation: See how recycling minimizes energy consumption, from mining and refining to transportation and manufacturing, while reducing carbon footprints.

Why India Needs Recycling:

India’s Green Push: With EV adoption and renewable energy storage on the rise, India is experiencing unprecedented demand for lithium-ion batteries. Our study explores how recycling can meet this demand sustainably.
Government Initiatives: Discover how initiatives like FAME and NEMMP are driving the market for EVs and lithium-ion batteries, making recycling an essential industry.

A Sustainable Future:

This report outlines how recycling lithium-ion batteries can conserve resources, protect the environment, and lower energy consumption, helping you navigate the complex but essential landscape of battery recycling.

What You’ll Get:

Comprehensive analysis of lithium-ion battery chemistry, design, and components.
The latest trends in battery technology and market demands.
Strategic insights into the benefits of recycling for resource conservation and environmental protection.
Actionable data for developing sustainable recycling practices in India and beyond.

LIBs Market Outlook:

A thorough analysis of the EV boom driving demand for lithium-ion batteries (LIBs).
Forecasts showing the explosive growth of EV sales from 10.5 million in 2022 to 27 million by 2026.
Insights into solid-state batteries, next-gen chemistry, and sodium-ion tech reaching commercialization.
Key data on global EV adoption rates by region—52% in China, 42% in Europe by 2026.

Battery Recycling Market Insights:

Market projections of US$5 billion in 2022 growing to US$23.6 billion by 2030 at a 21.4% CAGR.
A deep dive into regional developments, particularly in China, Europe, and the US, where end-of-life battery volumes are expected to surpass scrap production by 2030.
India’s growing market, with an anticipated $1 billion recycling opportunity by 2024, as the country’s recycling capacity scales up to meet the rising demand.

Key Industry Players and Global Capacity:

A comparison of leading global and Indian battery recyclers, showcasing their capacities and technologies.
Detailed breakdown of recycling methodologies, from mechanical to hydrometallurgical processes, tailored to the Indian market.
Profiles of top recyclers like Lohum, Attero (India), and their global expansion plans.

Strategic Opportunities:

Insights into government policies, subsidies, and regulations driving the localization of battery supply chains.
An exploration of the environmental benefits of recycled battery materials, which produce 4x lower carbon emissions compared to virgin materials.

Technical Feasibility:

Technology Solutions

Pre-treatment: Introduction to necessary pre-treatment methods, such as mechanical separation and thermal treatment, to prepare batteries for recycling.
Direct Recycling Method: Focus on preserving the cathode’s crystal structure to make recovered materials reusable with minimal treatment. This section includes steps like battery collection, sorting, shredding, and electrolyte recovery.
Pyrometallurgy: A high-temperature process used to separate metals from battery waste. It discusses techniques like smelting, calcination, and roasting to recover valuable materials such as cobalt, nickel, and copper from batteries.
Hydrometallurgy: A low-energy, highly efficient recycling process that uses chemical leaching to extract metals from the battery waste, minimizing environmental impact.

Site Feasibility

Location Assessment: Criteria for selecting the best plant site, including industrial zoning, access to utilities (power, water, etc.), transportation networks, and proximity to battery supply sources.
Utility Assessment: Detailed evaluation of the energy, water, and waste disposal requirements for operating a recycling plant, ensuring minimal environmental impact.

Process Flow

Proposed Phase Plan: A phased approach to plant setup, from initial construction and equipment installation to full operational capacity. Each phase is designed to optimize resource use and efficiency.
Process Flowchart: A visual representation of the recycling process, from battery collection and pre-treatment to final material recovery, offering a clear understanding of how the plant will operate.

Financial Feasibility:

Cost of Project

Detailed breakdown of the initial capital investment required for setting up the plant.
No. of scenarios are considered.
This section includes a comparison of costs for land acquisition, construction, machinery procurement, and initial operational setup.

Raw Material Cost

Year 1 to Year 5 projections for the costs associated with acquiring used lithium-ion batteries and other necessary raw materials.
Assessment of market volatility and expected fluctuations in material prices over the plant’s operational period.

Revenue Projections

Estimated revenue generation based on recovered materials like lithium, cobalt, nickel, and copper.
Separate revenue models for different country setups, factoring in machinery efficiency and product quality.
Revenue estimates for the first five years, including potential fluctuations based on market demand for recycled battery materials.

Profit and Loss Analysis

Profit and loss scenarios over the first five years of operation.
Projections based on different machinery setups, market prices, and operational costs.
Break-even analysis indicating how long it will take to recover the initial investment.
Risk factors such as raw material cost fluctuations and market demand changes are considered.

Regulatory & Legal Compliance:

Policies

Overview of critical battery and waste management regulations:
- Battery Management and Handling Rules (BMHR) 2001
- E-Waste (Management) Rules 2016
- Battery Waste Management Rules 2022
Amendments and updates to these policies and their impact on battery recycling operations.

Required Permits and Licenses

A comprehensive list of the permits and licenses needed to set up and operate a battery recycling plant:
- Land allotment approvals
- Pollution-related certifications (e.g., air and water quality permits)
- Business setup licenses
- Other necessary environmental clearances and operational permits.

Risk Screening and SWOT Analysis:

Risk Across the Value Chain

Analysis of risks at different stages, including:
- Collection and transportation of batteries
- Storage and handling risks related to safety and hazardous materials
- Recycling operations risks (e.g., environmental pollution, air quality issues, waste disposal)

SWOT Analysis

Strengths: Growing demand for recycled materials, strong market potential.
Weaknesses: High initial costs, regulatory challenges, and technical complexity.
Opportunities: Expanding EV market, global push for sustainability, growing need for critical materials.
Threats: Fluctuations in raw material prices, evolving regulations, competition from established players.

Supply Chain Dynamics of LIB Recycling Plant:

Proposed Phase Plan for the Project

A phased approach for the project setup, outlining timelines for:
- Initial procurement
- Construction
- Commissioning
- Full-scale operation

List of Contacted LIB Recycling Machinery Manufacturers

Detailed list of local and global manufacturers of LIB recycling machinery.

Raw Material Suppliers

Local and International Market Scrap Suppliers: Identifies suppliers for sourcing used batteries for recycling.
List of OEMs for Collaboration on EPR: Companies to collaborate with for Extended Producer Responsibility (EPR).

List of Potential Black Mass Buyers

Identifies the potential buyers for black mass (a critical output of battery recycling).

Chapter 1: Introduction

Chapter 2: Lithium-Ion Battery Recycling

2.1 Battery Chemistry & Design

2.1.1 Chemistry of Lithium-Ion Batteries

2.1.2 Battery Design

2.1.3 Charging and Discharging

2.2 Composition of Lithium-Ion Batteries

2.3 Schematic Diagram of LIBs and its Working Principle

2.3.1 Schematic Diagram of LIBs

2.3.2 Working Principle of LIBs

2.4 Need for Recycling and Reuse

Chapter 3: Market Overview

3.1 Global & Indian Trend, Market Growth & Dynamics

3.1.1 The LIBs Market

3.1.2 The Battery Recycling Market

3.2 Global and Indian Government Focus

3.2.1 Global Government Focus

3.3 Feasibility, Opportunity & Potential Future in Battery Recycling Business in India

3.4 LIBs recycling market segments based on several factors

3.5 Key Indian & Global Players in Battery Recycling Business

Chapter 4 LIB Recycling Technology

4.1 Pre-treatment

4.2 Direct recycling method

4.2.1 Battery Collection and Preparation

4.2.2 Material Separation

4.2.3 Binder removal and recovery

4.2.4 Product enhancement

4.3 Pyrometallurgy

4.3.1 Calcination & Roasting

4.3.2 Oxide Reduction & Smelting

4.3.3 Metal Refining

4.3.4 Recovering Cathode material

4.4 Hydrometallurgy

4.4.1 Leaching

4.5 Best suited method for recycling according to requirement of Local Market as well as overseas market

4.5.1. Summary of materials that can be recovered from different recycling plant

4.5.2 Advantages and Disadvantages of three major LIB recycling technologies

4.5.3 Why Mechanical + Hydrometallurgy is the best suited technology for Indian Market?

Chapter 5: Policies and Required Certificates & Documents

5.1: Policies

5.1.1. Battery Management and Handling Rules (BMHR), 2001

5.1.2 E-Waste (Management) Rules, 2016

5.1.3. Amendments in 2018

5.1.4. Battery Waste Management Rules 2022

5.2: Required Certificates & Documents

5.2.1: Land Allotment

5.2.2: Pollution related certifications and clearances

5.2.3: Other permissions and certifications

5.2.4: General Business Setup Licenses

5.2.5: Environmental Compliance for Setting Up for Lithium-Ion Battery Recycling Business

5.3: Entry barriers

5.4 Suggestions as per NITI-Aayog for a LIB Recycling Plant

Chapter 6: Setting of a Battery Recycling Plant

6.1 Significance of Location and Land Allotment

6.1.1 Significance of Location

6.1.2 Land Allotment

6.2 Sourcing of Raw Material including existing and Potential Vendors

6.3 The Battery Recycling Ecosystem

6.4 Power, Utilities, etc. Requirements

6.5 Ideal Plant Capacity Calculation as per Local Market Demand

Chapter 7: Raw Material

7.1 Data comparison of batteries being manufactured Vs batteries recollected for recycling

7.1.1 Past and Present Data of Manufacturing Vs Recycling

7.1.2 Estimated future data of manufacturing and recycling

7.2 Types of Input Material

7.2.1 On the basis of end use

7.2.2 On the basis of Size

7.2.3 Current Market samples

7.3 Reuse of batteries (The Secondary Market)

7.3.1 Future potential

7.3.2 Battery Reuse Applications

7.3.3 Approach to reutilize Spent batteries

7.3.4 Pricing details of second life batteries (SLB)

7.3.4 Technical challenges for reuses

7.4 Estimated input price

7.4.1 Breaking Down the cost of an EV battery Cell

7.4.2 Cost of New Cells V/s Value in End-of-life Cells

7.4.3 Trends in Prices of Critical Raw materials

Chapter 8. Recycling Process

8.1 Separation processes required for recovering materials and minerals

8.2 List of Recovered Materials and Minerals from LIB Recycling Process

8.3 Potential Use & Market of Recovered Materials and Minerals

8.4 Economic Value of Recovered Materials and Minerals

8.5 Handling & Disposal of Waste Coming Out of the Re-cycling Process

8.5.1 Treatment, Storage & Disposal Facilities (TSDFs)

8.5.2 An Indian Market Example

Chapter 9: Risk Screening for Battery Recycling Plant including SWOT Analysis

9.1 Risk across the value chain

9.1.1 Collection and transportation

9.1.2 Storage

9.1.3 Dismantling, refurbishing, and recycling operations

9.1.4 Air pollution

9.1.5 Waste disposal in landfills

9.2 SWOT Analysis

9.2.1 Strengths

9.2.2 Weaknesses

9.2.3 Opportunities

9.2.4 Threats

Chapter 10: Economics of a Battery Recycling Plant

Chapter 11 Business Plan for a Lithium-Ion Battery Recycling Plant

Chapter 12: Case Studies of big players in the market.

List of Figures:

Figure 1: Composition of Lithium-Ion Battery Pack

Figure 2: Schematic Diagram of Lithium-Ion Battery

Figure 3: Annual Metal demands from Lithium-Ion batteries

Figure 4: Sales of EVs in the near future globally & new passenger vehicle share by market

Figure 5: Estimated cumulative growth of the EV Sector over coming years

Figure 6: Estimated annual battery factory investment w.r.t different components

Figure 7: Increase in electricity demand with increase in number of EVs

Figure 8: Estimated annual growth of LIB Market in India

Figure 9: EV Sales in India as of 2022

Figure 10: Comparison of input material source - currently and in future

Figure 11: Battery Recycling Market Outlook by Region

Figure 12: Battery Recycling Market Outlook by Region

Figure 13: Carbon emissions by Virgin Raw Materials Vs Recycled Raw Materials

Figure 14: Flowchart for Lithium-Ion Battery Recycling Market Segments Based on Different Factors

Figure 15: Recycling Capacity across the globe in Tonnes/year

Figure 16: Prospect of Recycling Plant Business across the world

Figure 17: Flow of separation of material

Figure 18: Direct recycling process

Figure 19: Direct Recycling R&D – RE cell

Figure 20: Flow diagram for direct recycling processes of cathodes

Figure 21: The process of froth flotation

Figure 22: Re-lithiation

Figure 23: Cost comparison for Lithiation by different methods

Figure 24: The pyrometallurgy recycling process

Figure 25: Furnace used in Pyrometallurgy recycling

Figure 26: Ellingham diagram of several oxides

Figure 27: Flow of Hydrometallurgy

Figure 28: Hydrometallurgy Process

Figure 29: Comparison of recycling Technology

Figure 30: SWOT Analysis for Hydrometallurgy

Figure 31: Flow diagram for permissions required for setting battery recycling facility

Figure 32: Attero Recycling Plant

Figure 33: Exigo Recycling Pvt. Ltd.

Figure 34: Ziptrax CleanTech Pvt. Ltd.

Figure 35: Batx Energies Pvt. Ltd.

Figure 36: Lohum Cleantech Private Limited.

Figure 37: The Ecosystem of Battery Recycling.

Figure 38: The Flow process of Circular economy of Lithium-Ion Battery Recycling.

Figure 39: The Power and Utilities requirement for the LIB Recycling Plant

Figure 40: Prices of different component Lithium-ion batteries

Figure 41: 2019-2025 value of raw materials present in Li-ion batteries going for recycling (in $ million)

Figure 42: cell value of packs

Figure 43: Global demand of battery -2016 -2022

Figure 44: Annual addition of LIBs in Indian Market

Figure 45: Li-ion battery demand is expected to growth by 2030

Figure 46: Accumulative second life battery (SLB) capacity

Figure 47: Refurbished Battery Cost Breakdown

Figure 48: Skilled Technical Labour Across Countries

Figure 49: SLB re-purposing cost Categories

Figure 50:Break down of Lithium-Ion Batteries w.r.t cost

Figure 51: Comparison between cost of different components of new cells and End of life cells

Figure 52: Cost of critical metals for LIBs

Figure 53: Separation processes flowchart as per suggested technique in chapter

Figure 54 (a), (b), (c) & (d) – List of TSDFs in India with Addresses

Figure 55: Swot Analysis

Figure 56: Battery Recycling Plant Layout – Sample.

List of Tables:

Table 1: Composition of Li-Ion Batteries

Table 2: Different Cathode Composition of Li-Ion Batteries

Table 3:Category wise sales of EV in units

Table 4: List of India & Global companies in the Battery Recycling Business with their respective capacities

Table 5: Specifics of Pyrometallurgy

Table 6: Output through Hydrometallurgy

Table 7: Hydrometallurgy Treatment of LIBs

Table 8: Materials recovered from different process

Table 9: Advantage and disadvantage of different methods

Table 10: The global and local market based on different parameter

Table 11: Pollution related certifications and clearances

Table 12: Other permissions and certifications

Table 13: List of current vendors

Table 14: Potential Vendors

Table 15: Imports of EOL batteries from different countries

Table 16: Global demand for battery

Table 17: mobile phones battery weights

Table 18: laptop battery weights

Table 19: EV battery weights

Table 20: Way of Reusing

Table 21: Cost percentage of each cell component

Table 22: Component range of typical LIBs and commodity value of each metal element in 2020

Table 23: Summary about material breakdown in a regular EV battery pack with NMC cathode

Table 24: cost of each cell chemistry

Table 25: The price for different metals (for new metals)

Table 26: Prices of recovered materials and minerals: (As of Jan 2023)

Table 27: Risk mitigation measures during battery collection and transport

Table 28: Risk & mitigation measures for collection and transportation

Table 29: Risk mitigation measures during storage

Table 30: Risk and mitigation measures for storage

Table 31: Risk mitigation measures during dismantling and operations

Table 32: Risk and mitigation measures for dismantling and operations

Table 33: Risk mitigation measures related to air pollution

Table 34: Risk and mitigation measures for air pollution

Table 35: Risk mitigation measures to handle improper waste disposal

Table 36: Risk and mitigation measures for waste disposal

The rapid proliferation of Lithium-Ion batteries (LIBs) in various applications, ranging from portable electronics to electric vehicles (EVs) and renewable energy storage systems, has led to a surge in demand for energy storage solutions worldwide. This exponential growth, driven by a global shift towards sustainability and clean energy, has simultaneously brought to the forefront the issue of end-of-life battery disposal and the imperative need for sustainable lithium-ion battery recycling solutions. The recycling of Lithium-Ion batteries not only addresses environmental concerns related to battery waste but also plays a pivotal role in securing a reliable and cost-effective supply of critical raw materials such as lithium, cobalt, and nickel.

This comprehensive study aims to provide a detailed overview of the lithium-ion battery recycling industry, focusing on various aspects crucial for setting up and operating a successful recycling plant. The report explores the chemistry and design of lithium-ion batteries, the composition and schematic diagram of LIBs, and the imperative need for recycling and reuse in light of environmental sustainability and resource conservation.

Subsequently, the report delves into the market dynamics surrounding lithium-ion battery recycling, both on a global scale and within the Indian context. It analyzes the growth trends, government policies, and the potential opportunities within the battery recycling business, including segmentation of the recycling market based on various factors. Additionally, it highlights key players in the global and local battery recycling industry.

The recycling technology employed in battery recycling plants plays a pivotal role in the efficiency and profitability of the operations. This report provides an in-depth examination of various recycling methods in Chapter 4, including hydro, pyro, and direct processes, with a focus on determining the most suitable method based on the specific requirements of the local market.

Furthermore, the report will discuss the regulatory and policy framework necessary for establishing a battery recycling plant, outlining the essential certificates and documents required while addressing potential entry barriers in Chapter 5.

Setting up a battery recycling plant involves several critical considerations, including location, land allotment, sourcing of raw materials, building the plant ecosystem, and fulfilling power and utility requirements. The report will guide readers in these aspects, including the calculation of an ideal plant capacity in line with local market demand.

It also evaluates the raw materials used in manufacturing batteries compared to those collected for recycling, highlighting the types of input materials and the potential for reusing batteries in the secondary market. The recycling process is thoroughly examined, elucidating the separation processes required for recovering valuable materials and minerals. It details the list of recovered materials and minerals, their potential uses and markets, economic values, and the responsible handling and disposal of waste generated during the recycling process.

Moreover, the study conducts a risk screening for battery recycling plants, incorporating a SWOT analysis to assess the strengths, weaknesses, opportunities, and threats inherent in this business endeavor. It also provides an in-depth analysis of the economics of a battery recycling plant, including the overall cost considerations, estimates of capital and operational expenditures, and the financial model for Return on Investment (ROI). The research also offers a detailed battery recycling plant layout.

Finally, this study presents real-world case studies that exemplify successful battery recycling plant operations in the current market, drawing valuable lessons from their experiences and outcomes.

In summary, this research aims to provide a comprehensive guide for Companies for the sustainable and economically viable establishment of Lithium-Ion Battery Recycling Plants, addressing the pressing environmental, economic, and technological challenges in the Lithium-Ion battery recycling industry.

Li-ion Battery Recycling Plant Feasibility Study

Battery Chemistry & Design:

Composition & Materials:

The Growing Need for Recycling:

Why India Needs Recycling:

A Sustainable Future:

Technology Solutions

Site Feasibility

Process Flow

Cost of Project

Raw Material Cost

Revenue Projections

Profit and Loss Analysis

Policies

Required Permits and Licenses

Risk Across the Value Chain

SWOT Analysis

Proposed Phase Plan for the Project

List of Contacted LIB Recycling Machinery Manufacturers

Raw Material Suppliers

List of Potential Black Mass Buyers

List of Figures:

List of Tables:

Sample Copy Request Form

Sample Copy Request Form

Quick Contact

If you have any questions or need help, feel free to contact with our team.

(+91)1294085420

Solutions

Battery
Green Hydrogen
Hydro-Power
Solar

Work With Us

Why Join Us

Working at SCM Connexions
Benefits at SCM Connexions

About Us

Who We Are
Vision & Mission
Our Leadership

Registered Office :

D-202, Vatika Mindscapes, Sector 27D, Faridabad, Haryana-121003, India.

Get Directions

© 2024 SCMCONNEXIONS | All Rights Reserved | Privacy Policy