PyroGenesis claims primary testing success with battery recycler

PyroGenesis Inc., a plasma-based technology provider headquartered in Montreal, recently announced results of a primary testing campaign it conducted with what it describes as a “leading battery recycler.”

PyroGenesis signed a contract with the recycler to test its high-temperature plasma as part of the recycler’s material recovery and new battery production process. According to PyroGenesis, the recycler’s extensive research and development has proven the recovery potential of critical minerals such as lithium, nickel, cobalt, copper and more from batteries. Additionally, the testing agreement, which was inked last year, had a timeline target of the fourth quarter of 2025 to the first quarter of this year.

Separately, material samples from the tests were shipped to the battery recycler’s facility to confirm various performance, yield and chemistry measurements. PyroGenesis calls the tests a success, adding that they were witnessed by a team of client engineers at PyroGenesis’ facilities and confirmed the anticipated outcomes from using plasma in their specific application.

PyroGenesis says the results mean there could be a subsequent testing phase required which, if needed, would be expected to take place before the end of this year’s second quarter. PyroGenesis says the recycler’s goal would be to purchase an initial 1-megawatt plasma torch system, followed by a subsequent purchase of five 1MW plasma torch systems or one 5MW system. PyroGenesis claims its client has indicated a potential need for multiple 5MW torch systems, though there is no certainty as to if and when further tests may be required, or if any future torch systems would be purchased.

“As global electrification accelerates and the first major wave of large lithium-ion batteries approaches retirement, the test results we announced today confirm that plasma may be a valuable component in the manufacturing life cycle as the focus shifts from battery production to complete battery life cycle management,” says PyroGenesis President and CEO P. Peter Pascali. “The long-term sustainability and economics of the battery sector will increasingly depend on scalable, closed-loop recovery systems capable of repurposing high-value minerals into new battery manufacturing.”

Pascali says that by deploying technologies such as his company’s electric-based plasma torch systems, clients like the battery recycler can turn end-of-life batteries into a strategic resource and enable battery manufacturers to reduce exposure to commodity price volatility and supply chain constraints for critical minerals while lowering emissions, improving operational efficiency and strengthening supply security.

“These results are an important first step in confirming the broad-based impact that switching to plasma can have on this industry challenge,” Pascali says.