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value is sufficiently high.133 Nickel, chrome, and iron from EOL NiMH batteries are all recycled at INMETCO, and are processed and reclaimed into a stainless steel remelt alloy product. The input is mixed with coke and sent through a two-step furnace (rotary hearth). The output is a 25-lb (11-kg) metal bar (referred to as a “pig”), which is 13% nickel and 13% chrome, with the balance consisting of iron. The nickel and chrome are expensive and are essential to the stainless steel-making process. Any battery with nickel is therefore valuable to IMMETCO. 5.2.4 Glencore-Sudbury Integrated Nickel Operations, Sudbury, Ontario (Canada) Sudbury Integrated Nickel Operations (INO), a subsidiary company of global mining company Glencore (which merged with Xstrata in 2013), operates a large nickel and copper smelter in Sudbury, Ontario.134 The smelter’s capacity is 550,000 tonnes/year and it can produce 95,000 tonnes/year of nickel, copper and cobalt matte. While Sudbury INO has historically processed mostly small portable batteries, it is now handling large- format EV batteries as well. EV batteries do not represent a significant percentage of what Sudbury INO processes, but are a niche market that it wants to grow, specializing in cobalt-bearing batteries (the company invested $30 million in a rotary kiln incinerator to allow the processing of a wider range of battery types.). Batteries are processed either by direct introduction to a converter, or to a rotary kiln. Processing options for loads of batteries packaged in plastic are limited by the flammability of the plastic; these loads are directed to the rotary kiln where plastics are burned off, and all off-gases are treated through the afterburner to ensure that no dioxins are released. The company usually asks collectors to pre-treat the batteries to de-activate them, as well as break them down into small components (battery packs with 6 or 12 cells, or individual battery cells) due to the input feed size limitations of the rotary kiln. The cells or packs, once suitably sized, are introduced to the kiln/calciner for metals recovery in a pyrometallurgical process. The temperature in the molten metal bath is 1300 degrees Celsius. Lithium is captured in the slag (and is lost), and cobalt goes to the matte phase, where matte is produced through a hydrometallurgical chlorine process. Sudbury INO ships the cobalt matte to Glencore’s Nikkelverk Refinery in Kristiansand, Norway for further treatment.135 Glencore has stringent safety policies for evaluating new materials. They have put pressure on large battery designers and manufacturers to consider EOL when designing batteries and new battery 133 INMETCO. “Battery Recycling.”PDF Image | Reuse and Recycling of Batteries Employed in Electric Vehicles
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