At a glance
SNAM wanted to scale up the capacity of its pilot plant for the mechanical processing of Li-ion batteries from 500 tonnes to 5,000 tonnes per year.
After basic engineering, including separation tests, we designed the entire line. To get an accurate picture of the actual location where the installation was to be placed, we performed a 3D scan.
Lybover took care of the entire project coordination, including supervision of the installation work.
SNAM, Société Nouvelle d’Affinage des Métaux, was founded in Lyon in 1977 and moved to Saint-Quentin-Fallavier in Isère in 1981. In 1988, the head office moved to Viviez in Aveyron, where a second processing unit was opened. In 2024, SNAM Viviez contacted Lybover in search of solutions for the mechanical treatment of lithium-ion batteries. After initial experiences with a pilot plant, SNAM was ready to have a higher-capacity sorting line designed and built.
SNAM is a French company specialising in the recycling of nickel-cadmium (NiCd), nickel-metal hydride (NiMH) and lithium-ion (Li-ion) from used rechargeable batteries and industrial waste.The company recycles two types of batteries: portable batteries from mobile phones, laptops and wireless tools, and industrial batteries from aviation, railways, the military and electric vehicles.
Capacity expansion after successful tests with pilot plant
SNAM uses thermolysis to treat Li-ion batteries. This technology is a heat treatment process in a low-oxygen atmosphere in constantly monitored chambers. In this phase, the energy still present in certain batteries, known as residual energy, is removed. This thermal process also removes organic substances (plastic, paper, cardboard) and solvents (electrolytes). This is followed by separation by mechanical treatment. SNAM already had a pilot plant that could process 500 tonnes per year. This installation enabled SNAM to gain experience and prepare for the future capacity expansion to 5,000 tonnes per year. For this project, SNAM called on Lybover, which has extensive expertise in mechanical processing in various sectors and applications.
Optimisation and study of the processing line
In the first phase, we carried out basic engineering, including separation tests, and designed the initial plans for the line in the existing building. The material from the pilot setup was used as input for the separation test. This test involved collecting all relevant material and process data in order to develop the right solution. The process can be visualised using a flow diagram, which shows all transport methods, storage facilities, etc. A detailed mass balance was calculated and a principle diagram was drawn up. To get an accurate picture of the actual location where the installation was to be built, we carried out a 3D scan. This gave both the customer and Lybover a better understanding of the desired situation. After consultation, and based on all available plans and the technical and financial quotation, SNAM formalised its collaboration with Lybover for the installation of the new line.
Project coordination and integration
Within the multidisciplinary team dynamic, the selected components and machines were discussed in detail. Lybover took care of the entire project coordination, including supervision of the installation work. Some equipment and services were purchased by the customer, such as the shredders, support structures, mechanical assembly, and the feeding and filling of the big bags. However, Lybover remained responsible for the design and integration of all components.
The sorting line in detail
The processing line designed by Lybover comprises several steps that are crucial for the efficient recycling of Li-ion batteries. First, the material is fed into the line where it is shredded, reducing the batteries to smaller particles, which facilitates the subsequent steps.The shredded material is then screened into different particle sizes: from fine to coarse. This screening process is essential for separating the components and maximising the recovery of strategic metals.
The material flow is then subjected to magnetic separation to remove the ferrous metals, which can be reused or traded. The sorted fractions are collected in big bags, which makes it easier to manage the recovered materials. Lybover has also installed a complete extraction system for the processing line. By identifying the emission points, it was possible to select the appropriate filter technology and determine the required flow rates to ensure a clean and safe working environment.
The dust from the filter is transported pneumatically to the big bags and a centralised cleaning system ensures easy long-term maintenance of the processing line. Thanks to this careful coordination and integration, SNAM is able to recover every material for further processing or marketing, making an important contribution to the circular economy and the reduction of industrial waste.