Automating the reverse logistics of Li-ion batteries: disassembly at Circu Li-ion

The surge in electrification across various sectors has led to a significant increase in EoL lithium-ion batteries. Traditional manual disassembly methods are labour-intensive, hazardous, and costly, posing challenges for scalable and sustainable battery recycling and upcycling.

Circu Li-ion has introduced automated disassembly systems tailored for different battery types:​

Large Battery Packs (>2 kWh): Utilising robotic cells with flexible tooling, these systems perform tasks such as unscrewing, lid removal, and extraction of modules and components. The extracted parts are then sorted into upcycling (second-life applications) and recycling streams.

Small Battery Packs (<2 kWh): The process involves pre-diagnostic checks, automated dismantling using robotic arms, a patented cell extraction method to separate cells from busbars, and thorough cell diagnostics to assess parameters like State of Health (SoH) and internal impedance. This enables effective separation of cells for reuse or recycling.

Circu Li-ion operates on a 'Machine as a Service' model, providing hardware and software solutions to clients for a monthly fee. Their clientele includes original equipment manufacturers (OEMs) in EV, micromobility, and power tool sectors, as well as upcycling companies and battery recycling facilities.

Circu Li-ion's automated systems have achieved:​

Cost efficiency: Reduction of recycling costs by up to 30%.​

Environmental impact: Decrease in cell lifetime CO₂ emissions by up to 50%.​

Safety and scalability: Enhanced safety for workers and scalable solutions for battery disassembly.