Lithium-ion Battery Recycling Plant Setup in India

Developing a lithium-ion battery waste recycling factory in India requires a number of crucial actions, such as securing money, developing the recycling process, obtaining the required permits, and making sure that environmental standards are followed.

The market growth of electric vehicles led to an exponential increase in the utilization of lithium-ion batteries. We are witnessing an increase in electric vehicles everywhere, from public transportation buses to two-wheelers. To lessen the demand on natural non-renewable resources like CNG, diesel, and gasoline, the government is also providing subsidies for the purchase of electric vehicles (EVs). Now is the ideal moment to seize this business opportunity and establish a recycling plant for lithium-ion batteries in India. A recent estimate indicates that a 90% compound annual growth rate is anticipated for India's electric vehicle sector. Due to their high cost, four-wheelers are still falling behind, with this anticipated increase primarily affecting two- and three-wheelers.

What is Lithium-ion battery ?

A lithium-ion battery, commonly referred to as a lithium-ion battery, is a rechargeable Lithium battery. It is now widely used in many different electronic products. It's a kind of secondary battery that stores and releases electricity using lithium ions. Because of their high energy density, Li-ion batteries have the ability to store a large quantity of energy in a comparatively lightweight and tiny size. They are therefore perfect for portable electronics like tablets, laptops, and cellphones.

An anode and a cathode are the two electrodes that make up the battery. The Lithium ions battery can travel between these electrodes and between them during the charging and discharging cycles because the electrolyte keeps them apart. Lithium ions travel from the cathode to the anode, where they are stored, during the charging process. Conversely, when the battery is being used, or draining, the lithium ions return to the cathode. The device is powered by the electric current created by this movement. Graphite is usually used as the anode and lithium cobalt oxide, lithium iron phosphate, or other minerals are used as the cathodes.

What is Lithium ion battery or lithium ion recycling plant ?

The lithium ion recycling in a lithium-ion battery factory disassembles the batteries and extracts the constituent parts, producing raw minerals including manganese, nickel, cobalt, and lithium. These recovered raw materials are purchased by the producers so they can create fresh batteries. By doing this, we may lessen the amount of resources needed to meet the demand for Li-ion batteries for a variety of uses, therefore benefiting the environment.

Different Types of Batteries 

There are two kinds of batteries based on their core characteristics-

• Primary Battery: In our day-to-day activities, we utilize primary batteries. Although these batteries are straightforward and practical, we can only use them once. We have to replace it with a new one once it runs out of battery because we cannot recharge it. Primary batteries are typically used in toys, watches, torches, and remote controls.
• Secondary Battery: We are able to reuse and recharge secondary batteries on a regular basis. To replenish their energy, these batteries can be placed into a charger that is linked to an electrical outlet. Compared to its predecessor, these are more economical and environmentally beneficial because we don't need to buy new batteries as frequently. 

Benefits of Lithium lon Battery Recycling Plant

Lithium ion Recycling waste always contributes to the cleanliness and health of the environment by removing needless waste, particularly that which is hazardous to the environment due to its poisonous properties or the presence of dangerous compounds. In addition to using dangerous and poisonous chemicals during production, batteries have numerous advantages if they are recycled lithium batteries when their useful life is coming to an end. The following are a few of the main advantages of lithium ion recycling facilities:

• Reducing pollution

Batteries that are no longer needed are diverted to recycling facilities instead of landfills thanks to lithium ion recycling process. These landfills contaminate the earth, however Li-ion Battery Recycling Plants eliminate this issue entirely.

• Saving Money

When producers use recycled lithium batteries raw materials in their production, the cost of producing new batteries goes down. Cobalt, nickel, copper, manganese, and lithium are among the recycled lithium batteries raw materials that lithium-ion battery recycling plants supply.

• Conserving Resources

From used batteries, recyclers extract a variety of raw elements. By reducing our reliance, it not only saves money but also lessens the strain on our finite natural resources.

• Effectiveness of Energy Use

Large-scale energy savings are also achieved by setting up a lithium-ion battery recycling plant in India. Compared to the energy needed to refine the same material from natural ores, recycling spent batteries uses a far smaller amount of energy. By doing this, we significantly reduce our energy use, which in turn helps to lower greenhouse gas emissions and eventually stop climate change.

• Sturdiness

For the country to grow sustainably, we must minimize the exploitation of natural resources from the environment and treat waste by recycling waste that cannot be further processed into materials that can be used. And this aim will be aided by the lithium-ion battery recycling plant.

• Creation of Employment

The market's growing li-ion battery-operated gadget count indicates that battery waste recycling will soon prove to be a lucrative industry and generate job opportunities. Increased employment will also strengthen the economy of the nation by raising GDP (gross domestic product).

Methods of Recycling

Lithium-lon batteries can be recycled in a number of ways. Several often employed techniques include the following:

The Hydrometallurgical Method

Recycling companies use aqueous solutions to recover metals from their ores in a process known as hydrometallurgy. This technique aids in the recycling of lithium-ion batteries by separating the metal from the used batteries. Precipitation, electrolysis, and leaching are the procedures involved.

The Pyrometallurgical Method

Unlike hydrometallurgy, which uses chemicals, pyrometallurgy uses the smelting process. It disassembles the Lithium-ion Batteries before putting them into the furnace for heating. Preheating, pyrolysis, and smelting reduce the batteries in this process. By dividing the electrode materials into alloys and lithium concentrate, a selective arc furnace process can be used to recover the lithium. 

Physical Process Directed

Li-ion batteries are divided into numerous little cells during this process, and the recyclers use supercritical carbon dioxide to treat these cells. The same gas, known as supercritical CO2, is present at high pressure and temperature, when it transforms into a fluid and can be used to treat electrolytes. The recycler uses the sintering process to remove and regenerate the spent cathodes after extracting the treated electrolytes.

Machines Used in Lithium-lon Battery Recycling Plant

The recycler may need the following machinery to set up a Li-ion Battery Recycling Plant:

1. Shredder: In order to break down spent batteries into smaller bits for further processing, the recycler needs a shredder.
2. Granulator: To make the material easier to transport and treat by other equipment, the granulators shred it into smaller bits.
3. The system for pyrolysis consists of a furnace, condenser, and reactor. Using the Pyro Metallurgy Method, it is helpful to remove valuable materials from old batteries.
4. Separator: Using this equipment, different components produced in the Lithium Battery Recycling Plant—like copper and other materials—are separated for additional purification.
5. System for Treating Tail Gas: In this system, the recycler handles the gas that is created during pyrolysis.

Documents Required for Lithium-ion Battery Recycling Plant

The Li-ion Battery Recycling Plant uses hazardous trash, chemicals, batteries, and treatment procedures, all of which pose a threat to the environment. As a result, the authorities keep an eye on these enterprises and mandate that they adhere to all applicable regulations, collect the necessary paperwork, and fulfill all prescribed compliance requirements. The following are the essential documents needed to set up a lithium battery recycling plant in India:

1. Aadhaar and PAN of Responsible Person
2. Business Registration (NISME, Partnership, CIN etc.)
3. PAN Card of the Company
4. GST Registration of the Company
5. Udyog Aadhaar (if Applicable)
6. MoA and AoA of the Company
7. Consent Issued by SPCBs/PCCs under Air/Water Act and authorization under Hazardous & Other Waste (Management & Transboundary Movement) Rules, 2016
8. OTR under BMW rules 
9. Hazardous waste management authorisation 
10. Import Export Certificate issued by Ministry of Commerce & Industry (in case of importers)
11. District industries centre registration 

Process for Lithium-ion Battery Recycling Plant Setup in India

Establishing a Lithium-ion Battery Recycling Plant involves a number of steps, such as finalizing the property, preparing the necessary paperwork, setting up the machinery, and adhering to the law. The following is a step-by-step guide for setting up a Li-ion battery recycling plant:

Registration, Authorisation and Consent

1. The State Pollution Control Board must provide permission to the lithium-ion battery recycling. To establish the Li-ion Battery Recycling Plant, you need two consents: the Consent to Establish and the Consent to Operate.
2. Through an online consent management system run by the SPCB, the company can receive these consents. SPCBs are replaced in union areas by Pollution Control Committees.
3. The Battery Waste Management Rules stipulate that recyclers must receive the one-time registration. You must submit Form 2A to the State Pollution Control Board along with the aforementioned documentation in order to receive this authorization for the management of battery waste.
4. Following careful review of the application and the document, the SPCB will register the applicant in accordance with Form 2B format. The recycler is now able to run his recycling facility and recycle Li-ion batteries thanks to this registration.
5. The Hazardous Waste Management Rules are applicable to lithium-ion batteries. Therefore, in order to recycle Li-ion batteries, the recycler must also get a Hazardous Waste Management Authorization from the State Pollution Control Board.

Guidelines for filing of Application by Producers

1. Producers must first register on the website www.eprbatterycpcb.in. After that, they must fill out the application in six sections: (A) General Producer Information; (B) Battery Type Information; (C) Sales Data Addition; (D) Battery Material Addition; (E) Uploading Necessary Documents; and (F) Fee Payment
2. Applications pending registration grant will now be handled using the CPCB-developed https://egovernancecpcb.co.in/battery/ portal in accordance with this SOP's guidelines.
3. How to register: In order to file the registration application under the Battery Waste Management Rules, 2022, the manufacturer must create login credentials by supplying the information shown below. 

Step 1: Decide on the kind of application.

Step 2 - Company information, GST, company type, business address, PAN, and CIN to be entered

Step 3 - Information about the authorized individual working on behalf of the company must be verified, including their address, title, phone number, email address, and Aadhar number. A login must be established using the authorized email address and password, and the application must be filed. 

Filing section wise information 

1. Step 1 - Part A - General information - named and registered address of the producer 
2. Step 2 - Part B - type of product to be selected which is as mentioned in Annexure 1, battery type and composition, brand name and HSN code of the battery 
3. Step 3 - Part C - the details of the sale data to be enclosed, sales year, sale of battery, battery composition, quantity solid in sale year (Dry wt. in Kg) 
4. Step 4 - Part D - Add Battery Material - percentage composition of material in Battery
5. Step 5 - Part E - details of the GST number, Company PAN, CIN and TIN No. To be enclosed along with consent issued under Air/ Water Act and authorisation under Hazardous Waste Rules, DIC registration certificate. 
6. Step 6 - Part F - confirm and payment 

Process of making an application to set up Lithium-ion:

1. the application process takes in 15 working days. The registration shall be either granted/ rejected. 

1. Missing information shall be communicated to the manufacturer
2. Rejection of application shall occur when false/ irrelevant information/ document found in the application
3. With successful application, the portal generates a registration certificate duty signed by the competent authority
4. Member Secretary of the CPCB shall be the approving authority for issuing of the Certificate.
5. Fresh Registration shall be valid for a period of five years from the date of grant of registration.

Renewal of Registration

1. Producers and manufacturers must submit the application for renewal 60 days prior to the registration's expiration, together with the required paperwork, as covered in the preceding sections. Producers must make sure that Annual Returns for the intervening Registration period are filed by June 30th of the following year (per the rules). The processing of a renewal application won't begin until all required annual reports have been submitted.
2. The CPCB's audit findings will be taken into account when determining whether to renew registration.
3. Within 15 working days of receiving the required paperwork from the Producers, the CPCB will extend the registration given to the Producers for an additional five years.

Cancellation of Registration

1. If it is discovered that the document the Producers/Manufacturer supplied is fake, their registration may be revoked or suspended at any time.

1. In the event that Extended Producer Responsibility duties as outlined in Schedule II are not met, CPCB may suspend, terminate, or impose Environmental Compensation.
2. If the Central Pollution Control Board finds that the Producer has violated the Battery Waste Management Rules, 2022, it may suspend, cancel, or impose Environmental Compensation.
3. Within fifteen days after the notice date, the Producer/Manufacturers will have a chance to be heard before the CPCB considers canceling or suspending their registration.
4. An appellate authority will be the Joint Secretary or an official equivalent in the Ministry of Environment, Forests, and Climate Change.

Responsibilities of the Recycler

1. The recyclers are responsible for making sure that the procedures followed in order to recycle the lithium-ion batteries comply with the CPCB's criteria.
2. He must handle any trash that is created, manufactured, or processed in compliance with the guidelines set forth in the relevant solid, plastic, hazardous, or e-waste management rules.
3. The recycler is also accountable for taking out any used batteries from any equipment that he collects. Any gadget that has a waste battery installed should not be kept in storage.
4. Regular submission of quarterly returns to the CPCB site is required from the recycler.
5. Under these guidelines, recyclers should avoid doing business with any organization that did not register. During that time, it should also provide quarterly reports regarding lithium ion recycled batteries to the CPCB portal.
6. After recycling their batteries, the recyclers must give the parties the Waste Battery Recycling certificate. 

Lithium lon Battery Recycling Plant Cost and Fee

Setting up a Lition Battery Recycling Plant requires allocating funding to a number of different heads. The cost of setting up the land will depend on the type of transaction that needs to be completed first. It could be a lease, a buy, or both. After that, you'll need to buy the plant's necessary machinery. The Pyrolysis System, Shredder, Separator, Granulator, and other items are included. Following the installation of the necessary equipment, you must complete the necessary paperwork, which includes obtaining authorization, consent, and registration. Additionally, the government offers a range of incentives and services to small companies establishing lithium battery recycling plants in India.

The Battery Waste Management Rules of 2022 only let recyclers to register once, whereas the Hazardous Waste Management Authorization and the State Pollution Control Board's (CTE and CTO) consents must be renewed once their expiration dates. State-by-state variations in the cost of first issue or renewal are contingent upon the size of the firm. It ranges from Rs. 1,000 to Rs. 7,00,000 for companies with capital of at least Rs. 200 crore. These factors need to be taken into account while designing or establishing a lithium battery recycling plant in India, and funding should be allocated accordingly.

Note - Businesses can obtain additional information from the Ministry of Environment, Forests, and Climate Change (MoEFCC) as well as the CPCB website. These resources include comprehensive forms, instructions, and updates about battery management requirements.

For more specific inquiries or assistance with the registration process, companies can contact the CPCB directly or consult with environmental compliance experts.