Battery Recycling Process Overview

This process illustrates the preliminary processing steps for battery recycling through TCRW via EasyPak™ or our Bulk Pickups undergo. The process consists of:

Battery recycling receipt and inspection
Sorting of conforming batteries
(non-conforming batteries are returned to generator)
Material sizing
Metal recovery
Separation of final product
(Ni, Fe, Cr, Mn, & Zn-O)

Sizing and Alloying Details

Material Sizing

Material sizing is applied to the battery feedstock in order to equalize the heat transfer rate of the material. In order to heat the material evenly, all feedstocks placed into the furnace must be of equal size, or relative with respect to each other. For example, AAA and AA sizes heat evenly and so do C and D size units.

But a large change in the heat transfer rate between AAA and C or D size units exist, so mechanical sizing practices are applied in order to maintain optimum furnace performance (melt- rate). Lantern types require an additional process step for the same reasons already described.

Alloying Operation

The alloying operation is made up of a molten metal bath of nickel alloy. The battery types and sizes described above are fed into the molten bath at a temperature of approximately 2,800F. During this process step, a metal separation occurs which is actually the recycling step itself. During the amalgamation of the alkaline battery metals (low-temperature metals), with the existing molten metal bath (high-temperature metals), the separation of metals occurs.

Due to the large differences in the metals melting temperatures, the low-temperature metals cannot amalgamate with the high temperature molten metal bath (2800F); therefore, they must enter into a different phase – gaseous. In the gaseous phase, the low-temperature metals oxidize and separate, where they are collected as metal-oxides.

Final Product

High-Temperature Metal Alloy (Ni, Fe, Cr, Mn)
Recovery of the Low-Temperature Metal, Zn-O (Zinc-Oxide).

State Compliance

Battery Recycling Process Overview

Sizing and Alloying Details

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"No more challenges with fluorescent bulb and mercury recycling. We use the EasyPak recycling program and it is very simple and convenient for us."

"It’s easy to work with TerraCycle Regulated Waste. Their personnel are very friendly and knowledgeable about their products and the availability of them."

"I am very satisfied with all the services TCRW performs. They do what they say they are going to do, and they are here when they are scheduled to be here, and their paperwork is easy. Their representative is very helpful and informative about all phases of service."

"Excellent value for the money. The Bulb Eater® has immediately helped us reduce lamp storage and create a safer storage environment, while allowing us to add another item to our waste reduction efforts in the City of Auburn."

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Battery Recycling Process Overview

Sizing and Alloying Details

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State Compliance

"No more challenges with fluorescent bulb and mercury recycling. We use the EasyPak recycling program and it is very simple and convenient for us."

"It’s easy to work with TerraCycle Regulated Waste. Their personnel are very friendly and knowledgeable about their products and the availability of them."

"I am very satisfied with all the services TCRW performs. They do what they say they are going to do, and they are here when they are scheduled to be here, and their paperwork is easy. Their representative is very helpful and informative about all phases of service."

"Excellent value for the money. The Bulb Eater® has immediately helped us reduce lamp storage and create a safer storage environment, while allowing us to add another item to our waste reduction efforts in the City of Auburn."