The zigzag (ZZ) classifier is a sorting and classification device with a wide range of applications (e.g. recycling, food industry). Due to the possible variation of geometry and process settings, the apparatus is used for various windows of operation due to the specifications of the separation (e.g. cut sizes from 100 µm to several decimetres, compact and fluffy materials as well as foils). Since the ZZ classifier gains more and more interest in recycling applications, it is discussed in this paper, with regards to its design, mode of operation, influencing parameters and the research to date. Research on the ZZ-classifier has been ongoing on for more than 50 years and can be divided into mainly experimental studies and modelling approaches.

With the increasing number of electric vehicles (EVs) rises the need to recycle their used lithium-ion batteries (LIBs). During the mechanical process of the recycling of the LIB cells, a fine fraction, the so-called black mass, is created. This black mass consists mostly of the coatings originating from the cells’ electrodes and residues from the electrolyte, together with a low amount of Al and Cu from the crushed current collector foils. The amount of black mass as well as its composition is influenced by the chosen grid size at the crusher discharge. To reduce solvent emissions during the recycling process, a thermal pre-treatment can be added before crushing, which also influences the black mass and its properties due to changes in the adhesion between electrode foils and coating. This study investigates the influence of the crusher settings as well as the pre-treatment temperatures to find an optimum between the recovery of the coating and conductive salt, while limiting the amount of Al and Cu in the black mass.

Prior to the mechanical processing, discharging is necessary to prevent hazards. While the discharging process, different phenomena can occur changing the characteristics of the functional units of LIB. This study reveals the influence on the mechanical recycling and the obtained material when different discharge levels are used for various cells differing in their cell chemistry. It shows that for different cells, for example, copper deposits happen on the cathode as well as active material deposits on the separator foil. These new properties deteriorate the black mass quality and show contamination of the products with other material streams. It is being tested whether established sub-processes are suitable. However, it becomes clear that further recycling steps (e.g. flotation, hydrometallurgy) can be influenced as well as their product quality and element specific yield.

Lithium-Ion Battery (LIB) manufacturers produce different cell formats (prismatic, cylindrical, pouch, etc.) with different casing materials (steel or aluminium) and cell chemistries (e.g., NMC, NCA, LFP, etc.) for application in electric vehicles. By law, these cells have to be recycled after their lifetime. This study investigates the influence of different cell types on the outcome of a standardized mechanical recycling process consisting of crushing, sieving and air classification. The aim of the study is to find out whether different cell types can be processed together or whether the recovery and product quality can be improved by processing them separately. Pouch cells require low energy consumption for crushing compared to cylindrical and prismatic cells. Steel as a casing material increases the energy requirement during crushing compared to aluminium. The particle size distribution of several product fractions varies significantly between the different cell types. During air classification, the separator, anode, and cathode show a similar separation behaviour and can be processed with the same settings, whereas for the separation of the casing metals, different settling velocities need to be applied depending on the casing material.

For a two stage shredding and milling process the yield of black mass and the elemental recovery of critical elements Ni and Li s investigated. I can be shown that the quality of the products resulting from the mechanical recycling of lithium-ion batteries significantly depends upon the parameters employed during the shredding process. Modifications to the settings have the potential to exert a considerable impact on the particle size, liberation of composites and de-coating of electrodes. The discharge grid size employed during the first shredding step shows a significant influence on the downstream separation behaviour of the casing material and separator foil. The mill speed utilised during the second comminution step determines the separation achieved between the cathode and anode. A reduction in grid size employed during the first shredding stage results in an increase in black mass yield, although the recovery of the casing is diminished. In total Ni recovery for all setting combinations is similar, a lower recovery in the first shredding step is compensated by a higher recovery after the second comminution. It was observed that an overall increase in the mill speed above 1750 rpm resulted in elevated levels of copper contamination within the black mass. The influence of eleven distinct combinations of shredder and mill settings on the black mass yield and its composition, the recovery of the separator foil and the casing, as well as the separation behaviour of the anode and cathode, were investigated.

Considering the increasing demand for Li-ion batteries, there is a need for sophisticated recycling strategies with both high recovery rates and low costs. Applying optical sensors for automating component detection is a very promising approach because of the non-contact, real-time process monitoring and the potential for complete digitization of mechanical sorting processes. In this work, mm-scale particles from shredded end-of-life Li-ion batteries are investigated by five different reflectance sensors, and a range from the visible to long-wave infrared is covered to determine the ideal detection window for major component identification as relevant input signals to sorting technologies. Based on the characterization, a spectral library including Al, Cu, separator foil, inlay foil, and plastic splinters was created, and the visible to near-infrared range (400–1000 nm) was identified as the most suitable spectral range to reliably discriminate between Al, Cu, and other battery components in the recycling material stream of interest. The evaluation of the different sensor types outlines that only imaging sensors meet the requirements of recycling stream monitoring and can deliver sufficient signal quality for subsequent mechanical sorting controls. Requirements for the setup parameters were discussed leading to the setup recommendation of a fast snapshot camera with a sufficiently high spectral resolution and signal-to-noise ratio.