Advanced Battery Recycling Facility Development and Commissioning Intensive Course

Course Introduction

Battery recycling facilities are becoming increasingly important to the circular economy as electric vehicles, renewable energy storage systems, consumer electronics, and industrial battery applications expand worldwide. Recovering valuable materials from end-of-life batteries can reduce dependence on virgin mineral extraction, strengthen supply chain resilience, and support more sustainable manufacturing. The Advanced Battery Recycling Facility Development and Commissioning Intensive Course provides a comprehensive understanding of how battery recycling infrastructure is planned, designed, constructed, integrated, tested, and commissioned. Participants will explore the technical, commercial, environmental, safety, and operational requirements involved in developing facilities capable of receiving, processing, recovering, and managing materials from different battery chemistries while meeting applicable regulatory and performance expectations.

Battery recycling facility development requires careful coordination of feedstock supply, battery identification, safe receiving, storage, discharge where appropriate, dismantling, mechanical processing, material separation, hydrometallurgical or pyrometallurgical recovery, wastewater treatment, emissions control, and residual waste management. Each process stage introduces technical dependencies that influence throughput, recovery efficiency, product quality, operating costs, and environmental performance. Participants will examine how to translate feedstock characteristics and recovery objectives into process selection, equipment specifications, facility layouts, utility requirements, and integrated plant design. Particular attention will be given to differences between lithium-ion, lead-acid, nickel-metal hydride, and other battery types, recognizing that each chemistry requires appropriate handling procedures, process configurations, and material recovery strategies.

The engineering and construction of battery recycling facilities present significant challenges involving thermal runaway, electrical energy hazards, corrosive electrolytes, flammable solvents, toxic substances, dust, combustible materials, chemical reactions, and complex waste streams. Safe facility development requires these hazards to be considered from concept design through commissioning and routine operation. Participants will explore process hazard analysis, hazardous area considerations, ventilation, fire detection and suppression, emergency isolation, spill containment, environmental protection, and safe management of damaged or unidentified batteries. The course emphasizes the integration of process safety, occupational health, environmental controls, and engineering assurance into equipment selection, building design, control systems, commissioning procedures, and operational readiness reviews.

Successful commissioning depends on verifying that individual equipment packages operate correctly and that the complete facility performs as an integrated production system. Conveyors, shredders, separation equipment, reactors, filtration systems, furnaces, pumps, tanks, gas treatment equipment, water treatment units, and automated control systems must work together within defined operating limits. Participants will learn how to structure mechanical completion, equipment inspection, pre-commissioning, dry and wet testing where appropriate, control logic verification, interlock testing, process trials, performance acceptance, and documentation closeout. The course also addresses commissioning interfaces between original equipment manufacturers, engineering contractors, construction teams, laboratory services, utilities, waste contractors, and plant operators, with emphasis on preventing unresolved defects and incomplete procedures from compromising start-up.

Commercial and environmental performance must be demonstrated through reliable measurement rather than equipment installation alone. Recycling facilities need to verify throughput, material recovery rates, product purity, energy and water consumption, emissions, waste generation, operating availability, and compliance with product specifications. Participants will examine mass balance development, sampling plans, laboratory testing, process monitoring, traceability, quality assurance, and performance guarantee verification. The programme also considers digital plant monitoring, automation, predictive maintenance, data analytics, artificial intelligence-assisted process optimization, battery passports, extended producer responsibility, evolving recycling regulations, and emerging recovery technologies. These developments can improve transparency and efficiency when supported by sound data governance, validated procedures, and appropriate technical oversight.

By completing the Advanced Battery Recycling Facility Development and Commissioning Intensive Course, participants will be better prepared to manage the lifecycle of a battery recycling facility from project definition and engineering design through construction, commissioning, performance verification, and operational handover. They will develop practical capabilities in process integration, equipment readiness, contractor coordination, safety assurance, environmental compliance, commissioning management, production performance measurement, and continuous improvement. The course supports professionals seeking to establish reliable recycling capacity, recover valuable battery materials, strengthen resource efficiency, reduce operational risk, and deliver facilities that meet technical, commercial, environmental, and regulatory objectives.

Duration

10 days

Who Should Attend

• Project directors and project managers responsible for developing battery recycling plants, battery material recovery facilities, and circular economy infrastructure.

• Process engineers involved in battery dismantling, mechanical separation, hydrometallurgical processing, pyrometallurgical recovery, purification, and material recovery.

• Chemical engineers responsible for process design, reaction systems, chemical handling, mass balances, process optimization, and product quality.

• Mechanical, electrical, and instrumentation engineers coordinating production equipment, utility systems, electrical installations, automation, and process control integration.

• Construction managers and site supervisors responsible for civil works, equipment installation, piping, electrical systems, contractor coordination, and construction quality.

• Commissioning managers and engineers responsible for mechanical completion, pre-commissioning, functional testing, process trials, performance verification, and handover.

• Environmental, health, and safety professionals responsible for hazardous battery handling, fire prevention, chemical exposure, emissions control, waste management, and regulatory compliance.

• Plant operations managers preparing production teams, operating procedures, maintenance systems, shift arrangements, and operational readiness plans.

• Battery manufacturers, electric vehicle industry professionals, energy storage developers, and industrial organizations establishing recycling and material recovery capacity.

• Quality assurance and laboratory professionals responsible for sampling, analytical testing, recovered material specifications, traceability, and product acceptance.

• Procurement and contract management specialists coordinating process equipment suppliers, engineering contractors, technology licensors, commissioning vendors, and waste management providers.

• Project controls professionals responsible for integrated schedules, cost forecasting, risk registers, progress reporting, change management, and commissioning milestone tracking.

• Asset integrity and maintenance specialists responsible for equipment reliability, inspection planning, preventive maintenance, spare parts, and lifecycle performance.

• Sustainability and circular economy professionals assessing material recovery, resource efficiency, lifecycle impacts, recycled content, and responsible battery value chains.

• Consultants and technical advisers supporting battery recycling feasibility studies, facility design, process integration, commissioning assurance, and operational improvement.

Course Objectives

• Develop a comprehensive understanding of battery recycling facility development, including feedstock management, battery chemistry, processing technologies, material recovery, environmental controls, and plant commissioning.

• Evaluate battery recycling process options according to feedstock composition, target materials, recovery efficiency, product specifications, capacity, capital requirements, and operating costs.

• Translate facility production targets into process flow diagrams, equipment requirements, utility demands, material handling arrangements, plant layouts, and commissioning strategies.

• Coordinate multidisciplinary engineering interfaces involving mechanical processing, chemical recovery, electrical systems, instrumentation, automation, fire protection, utilities, and environmental treatment.

• Apply practical techniques for managing battery receiving, identification, segregation, storage, pre-treatment, dismantling, and preparation for downstream recycling processes.

• Integrate process safety, fire protection, hazardous material management, ventilation, spill control, emergency response, and occupational health requirements into facility development and commissioning.

• Develop commissioning plans covering mechanical completion, equipment inspection, system turnover, functional testing, control verification, interlock testing, process trials, and performance acceptance.

• Establish mass balance, sampling, laboratory testing, and data collection systems to verify throughput, recovery efficiency, product quality, waste generation, and process stability.

• Improve coordination among technology providers, construction contractors, equipment manufacturers, utility providers, laboratory teams, environmental specialists, and plant operators throughout project delivery.

• Strengthen environmental compliance by managing emissions, wastewater, hazardous residues, chemical storage, resource consumption, and appropriate treatment or disposal of process by-products.

• Apply project controls and risk management techniques to manage procurement dependencies, equipment delivery, commissioning interfaces, technical changes, cost exposure, and schedule uncertainty.

• Prepare an integrated facility readiness and performance improvement roadmap covering operational procedures, workforce competency, maintenance, compliance, reliability, and continuous optimization.

Comprehensive Course Outline

Module 1: Foundations of Battery Recycling Facility Development

• Examine the battery recycling value chain, including collection, transportation, receiving, safe storage, pre-treatment, material recovery, product finishing, and residual waste management.

• Compare the characteristics of lithium-ion, lead-acid, nickel-metal hydride, and other relevant battery chemistries and their implications for recycling processes.

• Identify the principal facility components, including receiving areas, processing lines, chemical treatment systems, utilities, emissions controls, laboratories, and material storage facilities.

• Evaluate the relationship between recycling capacity, feedstock availability, material recovery objectives, regulatory obligations, commercial viability, and circular economy outcomes.

Module 2: Feedstock Characterization and Battery Receiving Systems

• Establish procedures for receiving, identifying, weighing, documenting, inspecting, and segregating batteries according to chemistry, condition, source, and processing suitability.

• Assess how battery condition, state of charge, damage, contamination, packaging, and material composition affect handling requirements and process selection.

• Develop feedstock forecasting and inventory control methods that align supplier commitments, seasonal availability, storage capacity, production demand, and facility throughput.

• Establish traceability and acceptance procedures for managing unidentified batteries, damaged units, rejected loads, nonconforming materials, and incomplete supplier documentation.

Module 3: Recycling Technology Selection and Process Configuration

• Compare mechanical, pyrometallurgical, hydrometallurgical, and direct recycling approaches according to feedstock characteristics, target materials, recovery potential, and operating requirements.

• Examine process flow diagrams and equipment configurations for dismantling, size reduction, separation, leaching, purification, thermal treatment, and recovered product finishing.

• Evaluate technology maturity, process flexibility, throughput, energy requirements, chemical consumption, emissions, waste generation, and product quality expectations.

• Develop preliminary process selection criteria and technical decision records that connect facility objectives with engineering assumptions, commercial constraints, and environmental performance.

Module 4: Facility Layout, Process Design, and Engineering Integration

• Develop facility layouts that coordinate receiving areas, battery storage, processing equipment, chemical handling, laboratories, utilities, maintenance access, and finished product storage.

• Examine material flow, equipment access, segregation of incompatible activities, fire separation, ventilation requirements, vehicle movements, and safe personnel circulation.

• Coordinate process flow diagrams, piping and instrumentation diagrams, equipment specifications, utility balances, control narratives, and engineering deliverables across disciplines.

• Establish design review and interface management procedures for resolving equipment conflicts, layout constraints, utility dependencies, building interfaces, and changes to process requirements.

Module 5: Mechanical Pre-Treatment and Material Separation Systems

• Examine battery discharge where required, dismantling methods, casing removal, size reduction, shredding, screening, magnetic separation, and other appropriate mechanical pre-treatment processes.

• Evaluate equipment selection based on throughput, feedstock variability, particle size requirements, contamination control, material recovery, and maintenance accessibility.

• Establish controls for dust extraction, fire prevention, thermal monitoring, equipment isolation, combustible materials, and safe management of potentially reactive battery residues.

• Develop commissioning checks for conveyors, shredders, separators, feeders, extraction systems, guards, emergency stops, instrumentation, and interdependent material handling equipment.

Module 6: Hydrometallurgical and Chemical Recovery Systems

• Examine the principal stages of hydrometallurgical recovery, including leaching, solid-liquid separation, purification, precipitation, solvent extraction where applicable, and product recovery.

• Evaluate chemical handling requirements, reaction conditions, mixing, temperature control, reagent preparation, filtration, storage, and wastewater interfaces.

• Establish engineering and operating controls for corrosion, chemical compatibility, pressure and temperature limits, containment, dosing accuracy, and abnormal process conditions.

• Develop testing and commissioning procedures for tanks, pumps, agitators, filtration units, dosing systems, instruments, control loops, and chemical treatment equipment.

Module 7: Thermal Processing and Pyrometallurgical Systems

• Examine the role of thermal treatment, smelting, roasting, and related processes in recovering selected metals and treating appropriate battery-derived materials.

• Evaluate furnace systems, refractory materials, combustion or heating arrangements, feed systems, off-gas collection, temperature measurement, and process control requirements.

• Coordinate emissions control, dust collection, gas treatment, heat recovery where appropriate, and safe handling of hot materials and process residues.

• Develop commissioning checks for furnace auxiliaries, burners or heating elements, cooling systems, ventilation, interlocks, emergency shutdowns, and emissions monitoring equipment.

Module 8: Process Safety, Fire Protection, and Hazardous Material Management

• Identify hazards associated with stored electrical energy, thermal runaway, flammable electrolytes, reactive materials, toxic substances, corrosive chemicals, combustible dust, and high-temperature operations.

• Apply appropriate hazard identification and process risk assessment methods, including HAZID, HAZOP, bow-tie analysis, and other suitable techniques based on facility complexity.

• Integrate fire detection, suppression, isolation, ventilation, gas monitoring, emergency access, spill containment, and incident response provisions into facility design.

• Develop commissioning safety requirements covering permit-to-work systems, lockout and tagout, hazardous energy control, chemical introduction, emergency drills, and operational authorization.

Module 9: Utilities, Electrical Systems, Instrumentation, and Automation

• Assess facility utility requirements for electricity, water, cooling, compressed air, ventilation, process gases, heating, wastewater treatment, and other supporting services.

• Coordinate electrical distribution, motors, drives, transformers, protection systems, grounding, instrumentation power, and electrical isolation arrangements.

• Develop control system architectures involving programmable logic controllers, distributed control systems where applicable, safety systems, alarms, interlocks, and supervisory monitoring.

• Establish testing procedures for sensors, actuators, communication networks, control sequences, permissives, trips, emergency shutdowns, alarm priorities, and equipment integration.

Module 10: Environmental Management, Emissions, and Waste Treatment

• Identify potential environmental impacts involving process emissions, wastewater, dust, chemical residues, spent reagents, contaminated materials, noise, and waste storage.

• Design environmental control interfaces covering extraction, filtration, gas treatment, wastewater treatment, secondary containment, monitoring, and compliant residual waste handling.

• Develop sampling and monitoring plans for relevant emissions, effluents, waste streams, and environmental performance indicators according to applicable requirements.

• Establish procedures for environmental incident response, waste classification, contractor controls, documentation, reporting, and corrective actions for noncompliance.

Module 11: Procurement, Construction, and Contractor Coordination

• Develop procurement packages and technical specifications for processing equipment, tanks, pumps, conveyors, reactors, furnaces, filtration systems, control systems, and environmental treatment equipment.

• Coordinate supplier documentation, manufacturing inspections, factory acceptance tests, delivery logistics, storage conditions, installation requirements, and equipment preservation.

• Integrate civil construction, structural works, mechanical installation, piping, electrical systems, instrumentation, fire protection, and environmental infrastructure within the master schedule.

• Establish contractor coordination procedures for interface registers, quality inspections, technical queries, nonconformance management, change control, and worksite safety.

Module 12: Mechanical Completion and Pre-Commissioning Management

• Develop systemization strategies that divide the facility into manageable commissioning systems, subsystems, equipment packages, and turnover boundaries.

• Establish mechanical completion requirements covering installation verification, piping inspections, alignment, lubrication, electrical checks, instrumentation calibration, and documentation.

• Conduct pre-commissioning activities such as flushing, cleaning, leak checks, continuity tests, functional checks, equipment rotation verification, and utility readiness assessments as appropriate.

• Manage punch lists, defect classification, outstanding work, system handover certificates, preservation records, and formal acceptance of completed construction packages.

Module 13: Functional Testing, Process Trials, and Integrated Commissioning

• Develop commissioning sequences that progress from equipment-level testing through subsystem validation, utility introduction, controlled process trials, and integrated facility operation.

• Verify equipment functionality, process control responses, interlocks, alarms, emergency shutdown logic, utility stability, material handling, and environmental control performance.

• Coordinate the introduction of feedstock, reagents, thermal processes, and other operating inputs through approved procedures and documented readiness authorization.

• Manage commissioning deviations, process instability, equipment failures, corrective actions, retesting, and technical approval before progressing to subsequent operating stages.

Module 14: Performance Testing, Mass Balance, and Product Quality Verification

• Establish performance test protocols for throughput, operating availability, material recovery, energy consumption, reagent use, water consumption, emissions, and waste generation.

• Develop mass balance methods that reconcile incoming batteries, recovered products, intermediate materials, process losses, residues, and other relevant output streams.

• Coordinate representative sampling, laboratory analysis, material characterization, product purity testing, and verification against customer or contractual specifications.

• Prepare performance acceptance reports documenting test conditions, operating assumptions, measurement uncertainty, results, deviations, corrective actions, and achievement of applicable guarantees.

Module 15: Operational Readiness, Maintenance, and Digital Plant Optimization

• Develop operating procedures, maintenance plans, inspection schedules, spare-parts strategies, competency requirements, shift arrangements, and emergency response instructions.

• Establish operational readiness reviews covering staffing, training, permits, safety systems, environmental controls, quality procedures, supplier support, and unresolved commissioning issues.

• Examine digital plant monitoring, predictive maintenance, process analytics, automated material tracking, and AI-assisted optimization while maintaining appropriate human oversight and data governance.

• Establish ongoing performance management through reliability indicators, production dashboards, maintenance trends, product quality measures, environmental metrics, and continuous improvement reviews.

Module 16: Emerging Technologies and Integrated Facility Commissioning Capstone

• Examine emerging battery recycling developments, including improved recovery processes, direct recycling approaches, automation, robotic dismantling, advanced separation, and more efficient material purification.

• Assess evolving battery chemistries, extended producer responsibility, battery traceability, recycled material requirements, circular economy policies, and changing regulatory expectations.

• Complete an integrated case study covering feedstock characterization, process selection, facility design, safety systems, environmental treatment, equipment integration, commissioning, and performance testing.

• Present a comprehensive facility development and commissioning plan with interface responsibilities, project milestones, readiness criteria, risk controls, acceptance requirements, and long-term operational improvement measures.

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: training@upskilldevelopment.com Tel: +254 721 331 808

Training Venue 

The training will be held at our Upskill Training Centre. We also offer training for a group (at a discount of 10% to 50%) at requested location all over the world. The Onsite course fee covers the course tuition, training materials, two break refreshments, buffet lunch, airport transfers, Upskill gift package, and guided tour.

Visa application, travel expenses, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Upskill certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: training@upskilldevelopment.com, +254 721 331 808

Terms of Payment:

Unless otherwise agreed between the two parties’ payment of the course fee should be done 3 working days before commencement of the training so as to enable us to prepare better.