Ball Mill for Lithium-Ion Batteries: A Revolutionary Recycling Solution

As global lithium-ion battery scrap volumes reach millions of tons—projected to hit 2.8 million tons by 2025—the high energy consumption of traditional pyrometallurgical methods (>1500°C) and the severe acid pollution from hydrometallurgical processes (producing 5-8 tons of acidic wastewater per ton of waste batteries) pose significant challenges to meeting carbon neutrality goals. In contrast, ball mill for lithium-ion batteries offers a more sustainable solution. This mechanochemical technology enables atomic-level material reconstruction through room-temperature solid-phase reactions, cutting energy consumption for metal recovery by 83% compared to pyrometallurgy and reducing the use of leaching agents by 90%. This breakthrough is reshaping the technical landscape of lithium battery recycling.

Core Breakthroughs in Ball Mill for lithium-ion batteries

Mechanochemical Activation Mechanism

Selective Dissociation: By controlling the ball-to-material ratio (20:1) and rotation speed (400 rpm), lithium can be selectively extracted (efficiency >99%) from the LiNiCoMnO₂ lattice. As a result, this process enriches cobalt, nickel, and manganese in the solid state.

In-situ Reduction Reaction: A research team used imidazolium glycol ionic liquid as a medium. During ball milling, Co⁰ is directly reduced to soluble Co²⁺ by lattice oxygen. This eliminates the need for traditional reducing agents, such as NaHSO₃, and reduces toxic gas emissions to zero.

Particle Size-Activity Control: Plasma-assisted ball milling (P-milling) creates a crack network (10-50 nm) in the cathode material. This increases the specific surface area by 8 times and reduces the subsequent acid leaching time from 6 hours to just 30 minutes.

Process Innovation Matrix

Technical Route	Key Parameters	Recovery Efficiency (%)	Carbon Emissions Comparison with Traditional Processes
Organic Acid Co-Milling	2 mol/L Acetic Acid + 2 ml H₂O₂ @ 70°C	Li: 98.39	↓76%
Chloride Mechanical Conversion	PVC + LiCoO₂ Co-Milling (Ball Ratio 15:1)	Co: 90↑	No Acidic Wastewater
Low-Temperature Pyrolysis-Ball Milling	400°C Pretreatment + Subsequent Dry Grinding	Total Metal Yield >95%	↓89%

Industrial Application Case Studies

Closed-Loop Economy Demonstration

One company has developed a 20,000-ton annual processing line with the “live crushing – ball mill activation – air flow separation” process.

• Metal Purity: The Li/Co/Ni content in black powder reaches 99.82%/99.75%/99.68%, meeting the direct recycling standard of GB/T 34015-2017.
• Energy Performance: The process consumes only 78 kWh of electricity per ton of waste batteries (compared to 350 kWh for traditional wet processes). This reduces carbon emissions equivalent to planting 120,000 trees annually.

Cost-Benefit Analysis

Investment Cost: The ball mill for lithium-ion batteries system accounts for 38% of total investment, which is 52% lower than acid leaching equipment.

Operating Cost: The cost is 21,000 yuan/ton (compared to 38,000 yuan/ton for wet processes).

By-product Value: Recovered lithium carbonate has a purity of 99.9%, yielding a 15% premium.

Future Technology Extensions

• Intelligent Ball Milling System: The motion trajectory of grinding media can be controlled using AI-powered acoustic emission signals.
• Supercritical CO₂-Assisted: A U.S. institution has shown that ball milling at 7.4 MPa can increase electrolyte decomposition efficiency to 99.97%.
• Microbial-Mechanical Coupling: A research institute has developed an acid-resistant bacterial strain. This strain increases cobalt extraction by 12% during the post-ball milling bioleaching stage.

Conclusion

Ball milling technology, based on the principle of “physical activation replacing chemical dissolution,” is transforming lithium battery recycling. It shifts the process from “high-pollution treatment” to “atom-economy utilization.” Moreover with the EU’s new battery regulation (to be fully implemented in 2027), the recycling efficiency threshold will rise to 90%. As a result, this room-temperature, low-energy, zero-emission technology will become essential infrastructure for the global industrial chain. Over the next five years, mechanochemical methods are expected to increase their market penetration from 18% to 54%, with a CAGR of 29.7%.

Epic Powder

Epic Powder, with its cutting-edge ball mill for lithium-ion batteries and classification equipment, is well-positioned to support this technological shift. Moreover the company provides high-efficiency grinding and activation solutions tailored for lithium-ion battery recycling. These solutions help reduce energy consumption and minimize waste. Additionally, they enhance the purity of recovered materials. As the lithium battery recycling industry moves toward greener, more sustainable practices, Epic Powder’s innovative ball milling technology will play a pivotal role in advancing these processes globally.