Pyro-hydro technology

Pioneering battery recycling in Europe

In 2004, we took a bold step by launching research into battery recycling and developing our own proprietary technology, well ahead of industry trends.

In 2011, we commissioned a dedicated smelter for rechargeable Li-ion batteries in Hoboken, making Umicore a European pioneer in this field. The current facility has a capacity of 7,000 tonnes and can process a wide range of end-of-life batteries and production scrap.

We continually innovate and update our technologies and processes. A major upgrade in 2022 significantly broadened our capabilities, expanding the process to automotive batteries, which are expected to dominate future volumes.

Advanced battery recycling with pyro-hydro technology

Umicore’s proprietary pyro-hydro technology sets a benchmark for sustainable battery recycling. Designed for a large industrial scale, it offers a future-proof solution that meets the most stringent environmental and regulatory standards, including full compliance with the EU Battery Regulation, while achieving industry-leading metal recovery rates.

This unique process delivers:

• Closed-loop recycling with recovered battery-grade materials for use in new batteries
• Robust performance across evolving battery chemistries and designs
• Enhanced operational health and safety by design, minimizing exposure to hazardous and harmful substances
• Efficient resource use, with reduced waste, water and chemical consumption
• No external process energy need, but instead using the energy in the batteries themselves and recovering excess energy

How it works

Our patented process combines pyrometallurgy and hydrometallurgy to maximize efficiency and material recovery. By combining high-temperature smelting with a streamlined chemical refining process, we recover essential battery metals like nickel,

cobalt, copper and lithium. Our end products are battery-grade materials that can be used in the production of cathode materials for new batteries.

Step 1: Pyrometallurgy

In the high-temperature smelting stage, with temperatures above 1000°C, end-of-life batteries and production scraps are transformed into three clean output streams:

• A metal alloy of nickel, cobalt and copper
• A lithium-containing flue dust
• A clean slag suitable for use in construction

This autogenous process uses the energy contained in the materials themselves, eliminating the need for external energy input.

Step 2: Hydrometallurgy

Our lean hydro process efficiently separates and refines the metals into battery-grade salts. Thanks to the purity of the alloy produced in the pyro step, our process requires fewer steps, uses fewer chemicals, generates less waste and consumes less water. Lithium is recovered as lithium carbonate or lithium hydroxide, ready for use in new batteries.

With a recovery rate of over 95% for cobalt, copper and nickel and over 90% for lithium, we produce high-quality materials that feed directly back into the battery value chain.