15-24 Ton Per Day Complete Lithium Battery Recycling Plant

Designed for Indian Market | EV • BESS • Circular Economy

India is entering a decisive phase of electric mobility and renewable energy storage adoption. With rapid growth in electric vehicles (EVs), battery energy storage systems (BESS), solar-plus-storage projects, and consumer electronics, the volume of end‑of‑life lithium‑ion batteries is increasing sharply. Establishing domestic battery recycling infrastructure is therefore both a strategic necessity and a high‑potential business opportunity.

This project proposes the installation of a Lithium Battery Recycling Plant based on advanced mechanical separation technology, capable of processing mixed waste lithium‑ion batteries and recovering high‑value materials such as black mass, copper, aluminum, iron, plastics, and separator materials with recovery efficiencies of up to 98–99%.

The project is fully aligned with:

• India’s EV & ACC Battery Manufacturing ecosystem
• Atmanirbhar Bharat and import substitution goals
• Extended Producer Responsibility (EPR) framework
• Circular economy and ESG investment priorities

2. Indian Market Opportunity & Policy Alignment

2.1 Market Drivers in India

• Rapid EV adoption across 2W, 3W, passenger vehicles, and buses
• Expansion of grid‑scale and commercial BESS projects
• Growth of solar + storage installations
• Mandatory recycling obligations under Indian environmental regulations

2.2 Policy & Regulatory Alignment

The project directly supports India’s regulatory and policy framework, including:

• Battery Waste Management Rules (India)
• EPR compliance for battery producers and importers
• Resource recovery and domestic raw material security
• ESG‑focused financing and green lending

3. Project Description

3.1 Project Name

Lithium Battery Recycling Plant

3.2 Processing Capacity

• Continuous industrial processing of mixed waste lithium‑ion batteries
• Designed for scalable operation to suit regional demand

3.3 Input Materials

• EV battery packs, modules, and cells
• BESS / ESS batteries
• Consumer electronics lithium‑ion batteries
• Cylindrical, prismatic, and pouch cell formats

4. Final Products & Value Poposition

4.1 Recovered Products

• Black mass (rich in lithium, nickel, cobalt, manganese)
• Copper powder
• Aluminum powder
• Iron fraction
• Plastic materials
• Separator (diaphragm) materials

4.2 Commercial Advantage

• Multiple saleable output streams
• High demand from refiners, cathode manufacturers, and metal processors
• Reduced dependence on imported raw materials

5. Technology & Process Flow

5.1 Process Overview

1. Controlled battery feeding and conveying
2. Primary shredding for safe size reduction
3. Thermal conditioning and drying
4. Mechanical crushing and liberation
5. Screening and separator material recovery
6. Magnetic separation for ferrous metals
7. Grinding and size classification
8. Airflow and gravity‑based separation
9. Black mass collection
10. Enclosed dust handling and gas treatment

5.2 Technology Benefits

• Dry mechanical process (no wastewater)
• High recovery and purity levels
• Stable, proven industrial operation
• Modular design adaptable to Indian site conditions

6. Plant & Infrastructure Requirements

6.1 Land & Building

• Compact industrial footprint suitable for Indian industrial estates
• Flexible layout for brownfield or greenfield sites

6.2 Utilities

• Standard 3‑phase industrial electrical supply
• Optional compressed air and cooling systems

6.3 Manpower

• Low manpower requirement per shift
• Suitable for skill development and local employment

7. Machinery & Automation

The plant incorporates fully integrated systems for shredding, separation, screening, material handling, and environmental control, supported by:

• Centralized PLC‑based automation
• Interlocked safety systems
• Continuous monitoring for stable operation

Equipment construction utilizes carbon steel and stainless steel depending on functional and environmental requirements.

8. Environmental, Health & Safety (EHS)

8.1 Environmental Controls

• Multi‑stage dust collection systems
• Enclosed material transfer

8.2 Gas & Emission Treatment

• Neutralization systems
• Catalytic oxidation
• Activated carbon adsorption

8.3 Compliance

Designed to support compliance with Indian pollution control norms and best‑practice industrial safety standards.

9. Scope of Supply

9.1 Standard Supply (FOB China)

• Complete lithium battery recycling plant
• Mechanical processing and material recovery systems
• Electrical, automation, and control systems
• Environmental protection and emission control systems
• Interconnecting conveyors and auxiliaries

9.2 Auxiliary Systems

• Thermal conditioning and drying systems
• Cooling and compressed air systems
• Supporting mechanical and electrical auxiliaries

10. Implementation & Execution Strategy

10.1 Project Execution

• Design finalization
• Manufacturing and factory testing
• Shipment on FOB China basis
• On‑site installation and commissioning support

10.2 Timelines

• Optimized for fast deployment
• Phased expansion possible as market demand grows

11. Financial & Commercial Overview (Indicative)

• Capital investment dependent on configuration, automation level, and capacity
• Strong revenue potential from recovered materials and recycling services
• Favorable operating economics due to low manpower and dry processing
• Attractive medium‑term payback potential under Indian market conditions

12. Risk Analysis & Mitigation

13. Strategic Advantages for Indian Investors

• Entry into a high‑growth EV & energy storage supply chain
• Early‑mover advantage in organized battery recycling
• ESG‑aligned asset suitable for green finance
• Supports national goals of resource security and sustainability

14. Conclusion

The proposed Lithium Battery Recycling Plant represents a future‑ready, environmentally responsible, and commercially attractive investment opportunity for Indian buyers. With strong alignment to national policies, growing raw material availability, and rising demand for recycled battery materials, the project is well‑positioned for long‑term success.

This Master DPR is suitable for Indian industrial buyers, investors, banks, NBFCs, and government‑linked entities, and can be further customized for state‑specific or project‑specific requirements.