Client’s Intro: China Minmetals Corporation, one of China’s largest state-owned metals and mineral trading companies, sought to establish a state-of-the-art battery recycling facility to process end-of-life electric vehicle batteries.
Challenges
- Manual disassembly processes were hazardous for workers due to potential thermal runaway and chemical exposure
- Low processing capacity of only 200 batteries per day with manual methods
- Inconsistent material recovery rates averaging 75-80%
- Difficulty in handling diverse battery formats and chemistries
- Compliance with stringent environmental regulations
ALB Solution
- Automated Battery Sorting System: AI-powered vision system to identify battery types, chemistries, and conditions
- Robotic Disassembly Cells: Customized robotic workcells with specialized end-effectors for different battery formats
- Precision Discharge System: Controlled discharge process to minimize fire risks
- Material Separation Technology: Advanced separation techniques for copper, aluminum, black mass, and other valuable materials
- Integrated Safety Systems: Comprehensive fire suppression, ventilation, and emergency shutdown systems
- Real-time Monitoring: IoT sensors and data analytics for process optimization
Key Results
- Increased processing capacity from 200 to 1,000 batteries per day
- Achieved material recovery rate of 95%, significantly higher than industry average
- Eliminated manual handling risks with fully automated processes
- Reduced operational costs by 40% through automation and efficiency improvements
- Enabled 24/7 operation with minimal human intervention
- Exceeded environmental compliance standards with zero hazardous waste discharge