Black mass recycling plant setup License in India: A complete guide

OVERVIEW

Black mass is a powder-like substance obtained during the shredding of the waste lithium-ion battery from electric vehicles and consumer electronics. Batteries contain anode, cathode, electrolyte and other critical metals. These components turn into black mass after the processing of the battery. It contains lithium, cobalt, aluminium, copper, nickel, manganese, iron,  and graphite along with some residual electrolytes. Black mass contains components which can be used as a secondary raw material in the EV battery manufacturing.

What is the black mass?

Lithium-ion batteries used in the electric vehicles are comprised of valuable metals such as lithium, copper, manganese, cobalt, and nickel. Once the battery reaches end-of-life, it is discharged, dismantled and then recycled to give a black-coloured, shiny, metallic and powdery mixture called 'black mass'. The black colour is due to the high concentrations of graphite contained in the anodes of batteries,, as the black mass contains valuable metals that make up battery anodes and cathodes.

Black mass makes up about half of the total weight of an EV battery. Batteries like nickel manganese cobalt, lithium iron phosphate, lithium cobalt oxides, etc. have valuable metals, and after recycling of the black mass, these metals are recovered to be used as the secondary raw material in the manufacturing of the electric vehicle battery components.

How is black mass made?

Recovery and processing of the black mass moves through collection, pre-processing, extraction and product recovery. Extraction of black mass is done mainly through two main processes. 

There are two main processes to producing black mass:

Pyrometallurgical Extraction: It is a heat-based extraction and purification process.

In this process of black mass extraction, high temperature is used to burn off the unwanted materials like plastics and remaining electrolyte. This process gives hazardous emissions and waste as byproducts. This process results in less recovered material.

Hydrometallurgical Extraction: In this process, back mass is dissolved in leach solution (H₂SO₄ or HCl combined with a reducing agent) to dissolve the metals. Once the junk metals like aluminium, copper and iron are recovered using a base, remaining metals like nickel, cobalt and manganese are extracted using a solvent extraction method. These are then purified and converted into battery-grade salts. 

Other products like graphite, copper, and aluminium are recovered from the black mass by physical sorting. 

What are the benefits of black mass recycling?

Recycling of black mass has significantly reduced the import dependence of India on other countries for valuable metals like lithium, cobalt, nickel, manganese, etc. Black mass is considered a hazardous material as per the MoEFCC list of “hazardous waste”. It has combustible and toxic properties. 

1. To promote the black mass recycling plant setup in India, the government has approved an INR 15 billion incentive scheme for critical mineral recycling under the National Critical Mineral Mission. 

2. Black mass recycling can reduce the import dependence and contribute to a circular domestic battery supply chain. Recyclers equipped with the latest machines and technology recycle the recovered material into battery-grade minerals, cathode active materials (CAM), and anode active materials (AAM). 

3. Recycling black mass is a sustainable process, as using primary metals for the manufacturing of EV batteries can be a cost-intensive process. 

4. Black mass recycling can prevent the contamination of water bodies, as direct disposal of waste batteries in land fills and rivers can cause high environmental catastrophes. 

5. EPR credit to PIBOs makes the black mass recycling a profitable business. These firms prefer to procure EPR credits from black mass recyclers offering them significant profits. 

 

Documentation and compliance requirements for the Black mass recycling plant set up License:

CPCB has a standard operating procedure (SOP) for the utilisation of black mass generated from the recycling of the EV batteries. With proper documentation, there is a significant reduction in the disposal of batteries in landfills. 

A black mass recycling plant setup in India requires strict regulatory compliances as per the Battery Waste Management Rules (BWMR), 2022, and the Hazardous and Other Wastes Rules, 2016. 

The list of documents includes mandatory corporate, land, and environmental clearances from the concerned authorities. 

1. GST registration certificate
2. Plant Payout
3. PAN number associated with the business
4. Industrial land allotment documents
5. Local body approvals
6. Consent to establish (CTE) issued by SPCB
7. Consent to operate (CTO) issued by SPCB under water and air acts
8. Hazardous waste authorisation certificate issued by SPCB/PCC under the hazardous and other wastes (management and transboundary movement) rules, 2016. 
9. Recycler registration on the CPCB battery waste EPR Portal for applicable recycler categories R2, R3 or R4.
10. Approval from concerned SPCB/PCC
11. District Industries certificate (DIC)

Why Choose EnviroXperts?

India is driving high on the EV revolution, and there is a global shift towards sustainable practices. This emphasises the significance of the recycling process. EnviroXperts is a renowned E-waste management and license consulting firm serving clients all over the globe. Recyclers and businesses dealing in the battery recycling get complete assistance in regulatory and compliance solutions as mandated by the government of India. We assist our client in the black mass recycling plant setup and help them to reuse, repurpose, and recycle used lithium-ion batteries for recovering valuable metals. These metals are reused in the EV industry and play an important role in boosting the circular economy of India. 

EnviroXperts assist recycling businesses in:

1. Providing fast approvals
2. Plant layout and machinery guidance
3. Complete application process
4. Higher amount of Black mass recovery
5. Environmental and pollution compliances
6. EPR support to PIBOs

Frequently Asked Question (FAQ`s)