Cracking the Code of Black Mass: How to maximize Value in Battery Recycling

As electric vehicles (EVs) take over the roads, another revolution is quietly happening behind the scenes – the battery recycling. And at the heart of this movement is black mass, the gritty, powdery residue left behind after shredding spent lithium-ion batteries. Packed with valuable metals like nickel, cobalt, and manganese, black mass holds huge potential — if you know how to analyze it properly.

The Problem: Black Mass Isn’t Simple

Every battery is different. Depending on the model and chemistry (NMC 111, 622, 811… or LFP), the black mass they leave behind can vary wildly in composition. A typical 60 kWh NCM EV battery might contain anywhere from 5 to 39 kg of nickel, and 5 to 11 kg of cobalt and varying concentration of manganese.

That’s a big range – and traditional lab analysis methods can’t keep up. Sampling errors, delayed results, and inconsistent data all add up to inefficiencies and lost value.

The Solution: A Complete Analytical Toolkit

To unlock the full value of black mass, recyclers need more than just basic testing. They need a multi-step, multi-instrument approach. Here’s what that looks like:

• Real-time bulk analysis: Use CNA Pentos neutron activation technology to scan 100% of your incoming black mass or the battery modules and packs right on the conveyor belt — no sampling, just instant, accurate data.

• Crystalline phase ID: Not all black mass is the same. With the Aeris XRD, you can quickly determine if you’re working with NMC, LFP, or something in between — and choose the right processing route.

• Homogeneous sample prep: Black mass is highly variable. Fusion systems like Eagon 2 and FORJ make uniform samples that ensure your lab tests are accurate and repeatable.

• Fast elemental analysis: Tools like the Epsilon 4 and Revontium XRF analyzers give you detailed breakdowns of metal content — fast and non-destructively.

• Inline process control: Keep an eye on your leaching efficiency in real time with Epsilon Xflow, an inline XRF system that monitors liquid metal concentrations during extraction.

• Particle size optimization: With Mastersizer laser diffraction, you can fine-tune particle sizes to boost leaching rates.

Why It Matters

The better you understand your black mass, the more efficiently and profitably you can recycle it! A complete analytical strategy means:

• Higher recovery rates
• Lower reagent costs
• Real-time process optimization
• Better handling of diverse battery chemistries

Power the Circular Economy

Recycling isn’t just about waste management anymore — it’s about resource recovery and closing the loop on battery materials. With the right analytical tools, you can turn complex black mass into a high-value opportunity.

Want to learn more about optimizing your battery recycling workflow? Get in touch — we’ll help you build the analytical toolkit you need to power the future.