u/Yezi_Cat

I’ve seen different explanations of how lithium-ion batteries are handled during recycling.

Some say the batteries need to be fully discharged before shredding. Others mention enclosed, low-oxygen systems that can process batteries even when some charge remains.

Is the second approach commonly used at an industrial scale? If so, what actually keeps the process safe—oxygen control, temperature monitoring, gas treatment, fire suppression, or a combination of these?

Not looking for DIY instructions. I’m just trying to understand how commercial recycling plants deal with this risk.

I’ve been reading a bit about how old EV batteries are recycled. The basic process sounds fairly straightforward on paper: discharge the batteries, shred them, separate the black mass, and recover the useful materials.

But I’m guessing it gets much more complicated at an industrial scale.

For people familiar with this industry, what usually causes the biggest problems? Is it fire risk, different battery chemistries, dust and gas treatment, material loss, or simply equipment wear and downtime?

I came across this topic while doing some research for work and would be interested to hear from anyone with real-world experience.