Increasing metal recovery in household battery recycling

Summary:

Relux is a German SME specializing in battery recycling, using advanced tech to recover metals like iron, copper, and zinc from shredded batteries.

Main description:

Relux Rohstoffe GmbH & Co. KG, founded in 2009 and based in Bad Oeynhausen, Germany, is a medium-sized, family-owned enterprise specializing in advanced recycling technologies. With 75 employees, Relux has evolved from its roots in the Kottmeyer forwarding company, established in 1951, into an internationally active player in the resource recovery and environmental technology sector.

The company focuses on the processing of secondary raw materials with a strong emphasis on the environmentally responsible recycling of used batteries. Over the years, Relux has developed and implemented innovative systems aimed at improving the material recovery rate of valuable metals such as iron, copper, and zinc from post-consumer batteries. In earlier stages, the company’s battery recycling method faced limitations, particularly in separating metallic fractions from the so-called “black mass”—a complex mixture of fine particles resulting from shredded batteries. These valuable metals were historically lost in downstream metallurgical processes, significantly reducing recovery efficiency.

In response to this challenge, Relux invested in modernizing its sorting and separation technologies. The upgraded process allows for precise mechanical separation of the metal components before further treatment, leading to a higher recovery rate of reusable raw materials and reducing reliance on energy-intensive smelting. Today, Relux plays a leading role in sustainable battery recycling, helping to close material loops and conserve critical resources.

Website: http://www.relux-umwelt.de

Resources needed:

Relux’s improved battery recycling system uses advanced mechanical separation technologies to recover metals like iron, copper, and zinc from shredded batteries. The company invested around €2.2 million in the project, with €440,000 funded by North Rhine-Westphalia’s circular economy program. The process upgrade required specialized sorting equipment, shredders, and emissions control systems. With 75 employees, Relux relies on skilled technical staff, engineers, and environmental specialists to operate and manage the system efficiently and in compliance with safety regulations.

Environmental benefits:

The new, resource-efficient recycling process reduces the proportion of black mass by 20 percent. This means that around 480 t of iron, 480 t of copper, and 240 t of non-ferrous metals can be returned to the raw material cycle each year.

resource Savings *

iron: approx. 480 t/a

copper: approx. 480 t/a

Non-ferrous metals approx. 240 t/a

CO2 equivalents approx. 4,000 t/a

*based on a recycling capacity of 12,000 t per year.