Complete EV Battery Packs
End-of-life traction battery packs removed from electric or hybrid vehicles and requiring pack-level dismantling before downstream recycling.
EV Battery Recycling Solution
EV Battery Recycling Solution
Prepare end-of-life EV battery packs and modules for safe mechanical recycling, then recover black mass, copper, aluminum and other material fractions through a configurable downstream process.
02 / Feedstock
EV battery materials this solution is designed to process
This solution is intended for end-of-life EV battery packs, modules and prepared battery assemblies. The final route depends on pack architecture, state of charge, dismantling level and downstream recovery objectives.
EV Battery Modules
Battery modules removed from packs and prepared for testing, discharge, dismantling or downstream mechanical processing.
Prepared Module Assemblies
Modules or subassemblies with external pack structures, major busbars or incompatible components already removed.
EV Battery Cells
Cylindrical, prismatic or pouch cells recovered from dismantled EV modules and prepared for the selected recycling route.
Pack / Module Production Scrap
Off-spec, rejected or obsolete EV battery pack, module or cell assemblies generated during manufacturing or assembly.
03 / Target Recovered Materials
Output fractions this solution is designed to recover
EV battery recycling can generate recoverable structural metals, conductive materials and active-material-rich fractions at different stages. The final outputs depend on dismantling depth, battery design and downstream processing requirements.
Black Mass / Active Material Fraction
Fine active-material-rich fraction recovered after controlled crushing, screening and separation of prepared EV battery cells or modules.
Copper-Rich Fraction
Copper-bearing material recovered from conductors, current collectors, busbars and downstream separated fractions.
Aluminum-Rich Fraction
Aluminum recovered from pack housings, module structures, current collectors or downstream metallic fractions.
Ferrous Metal Fraction
Steel or other magnetic material recovered from pack structures, fasteners, cell casings or prepared feedstock where applicable.
Plastic / Separator Fraction
Lightweight polymer-rich fraction separated from prepared battery material after mechanical processing.
04 / Recommended Recycling Process
Recommended process logic for EV battery recycling
This is recommended process logic, not a fixed production line. Pack dismantling, discharge, module preparation and downstream recycling stages are selected according to battery design, residual energy, capacity and target recovered materials.
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01
Pack Characterization & Safety Check
Confirm pack model, dimensions, state of charge, enclosure structure, module layout, electrical condition and target recovery route before dismantling begins.
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02
Pack Dismantling
Remove covers, structural parts, wiring, control components, cooling elements and other pack-level assemblies to access battery modules.
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03
Module Testing / Discharge / Preparation
Evaluate and prepare battery modules for the selected downstream route using appropriate testing, discharge, isolation or controlled dismantling measures.
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04
Module / Cell Size Reduction
Process prepared modules or cells through suitable opening and size-reduction stages to support downstream material liberation.
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05
Screening & Physical Separation
Classify the processed material and apply suitable magnetic, air, gravity or other physical separation stages to separate metal-rich, active-material-rich and lightweight fractions.
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06
Fine Fraction Collection & Output Handling
Collect black-mass-rich fines and separated copper, aluminum, ferrous and polymer fractions while coordinating dust and exhaust-control requirements.
Stages can be added, skipped or reordered after pack characterization and project review. Discharge method is project-specific and is not fixed to one technique.
05 / Safety & Environmental Control
Safety and environmental control
Residual energy and process-environment control
Coordinate isolation, testing or discharge, controlled feeding, dust collection and applicable exhaust treatment with pack dismantling and mechanical recycling.
05 / Recommended Production Lines
Complete process systems that support this solution
Recommended production lines cover pack/module preparation, optional discharge and the downstream mechanical recycling stages used after EV batteries have been made process-ready.
Request a Technical Proposal
Share your EV battery format, dismantling condition, required capacity, target recovered materials and site constraints so BREM can prepare an initial technical proposal. You do not need every technical detail confirmed before contacting BREM.