RecycleKaro’s battery recycling operations in India | Chat with Rajesh Gupta

RecycleKaro is a company that specializes in recycling electronic waste (e-waste) and lithium-ion batteries. In our conversation with Mr. Rajesh Gupta, Founder & Director of RecycleKaro, we gain insights into the company’s role in sustainable recycling practices. Mr. Gupta elaborates on their recycling processes and discusses the upcoming commercial launch of their Nickel Metal Plant, slated for March 2024.

What is the current scale of recycling at RecycleKaro? Please provide a breakdown of the current scale of both phases of recycling – (1) Mechanical separation or black mass production and (2) Black mass refining.

Our current recycling capacity stands at 7500 metric tons annually for e-waste and 2400 metric tons annually for lithium-ion battery recycling.

During the initial phase, known as Mechanical Separation or Black Mass Production, our facility operates with a crushing capacity of 180 metric tons per month for batteries, processing black mass at an average rate of 90 metric tons monthly.

Upon collection and disassembly of used lithium-ion batteries, their cells are mechanically separated from casings, achieving a 98% isolation of copper, aluminium, and plastic. The resultant residue, the black mass, holds critical metals like lithium, cobalt, nickel, and manganese. This black mass undergoes a hydrometallurgical process, utilizing leaching and solvent extraction to recover these vital metals—specifically, lithium, cobalt, nickel, and manganese.

As we transition to the Black Mass Refining phase, our meticulous process yields valuable outputs. On average, we refine 50-60 metric tons of Cobalt Sulphate, 2-3 metric tons of Nickel Sulphate, 1-2 metric tons of Manganese Sulphate, and 2-3 metric tons of Lithium Carbonate.

Please tell us about how Recyclekaro manages the collection of spent Li-ion batteries.

We acquire end-of-life lithium-ion batteries through diverse channels, including recycling contracts with OEMs, corporate recycling contracts, auction participation, and sourcing from aggregators.

Given the changing trend of types of LIBs coming into end-of-life, are you planning different processing lines for LFP, NMC and other chemistries?

We’ve successfully set up processing lines tailored for various types of lithium-ion batteries. Our state-of-the-art plant is equipped to efficiently recycle a wide range of lithium-ion battery chemistries, including NMC (Nickel Manganese Cobalt), NCA (Nickel Cobalt Aluminium), LFP (Lithium Iron Phosphate), LCO (Lithium Cobalt Oxide), LMO (Lithium Manganese Oxide), and LTO (Lithium Titanium Oxide).

Any comments on the economic viability of recycling end-of-life LFP batteries?

Lithium Iron Phosphate (LFP) batteries have diverse applications, from Energy Storage systems and Backup Power Systems to Portable Electronics and Electric Vehicles (EVs). With the increasing use of LFP batteries in EVs, there’s an expected surge in the availability of end-of-life batteries. Recycling these batteries has proven to be economically feasible. Our proprietary, patented technology for LFP battery recycling achieves an extraction rate exceeding 95% for lithium, ensuring a purity level exceeding 99.96%. Leveraging India’s ample raw material supply, logistics for transporting batteries in bulk quantities become more manageable.

Location of your LIB recycling plant & Nickel metal plant

i) Evergreen Lithium Recycling address: Gut no. 157/2, Wada Manor Road, Village Posheri, Tal. Wada, Dist., Palghar 421303

ii) The nickel plant will be located in the same area, with the address above

iii) The black mass refining process also occurs in the same address.

What is the current status of Nickel production at Recyclekaro?

RecycleKaro’s Nickel plant pilot project is operational, marking a significant step forward. The commercial plant construction is underway, and we anticipate commencing commercial production by March 2024.

What kind of companies in India would buy nickel metal compounds produced at your facility? Any information about the domestic demand for nickel metal compounds will be useful.

India typically consumes around 45,000 metric tons of Nickel Metal every year, a substantial majority of which, about 95%, is currently fulfilled via imports. This presents an exciting opportunity for domestically produced Nickel Metal. Our main target customers will include steel manufacturers and emerging battery production entities within the country.

Also read: RecycleKaro to invest INR 100 crore in Nickel Metal Plant to meet EV battery demand