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How are EV batteries dismantled safely here?

Before an EV battery can be recycled, it first has to be removed and dismantled. This is done by trained operators who leave nothing to chance. Geert Allard, Operational Manager at Sortbat (Bebat subsidiary) tells us more about this painstaking specialist’s task.

EV batteries have to be expertly dismantled by trained operators using appropriate tools, wearing protective gloves and following general safety guidelines. Allard: ‘Our employees are skilled in both mechanical and electrical engineering. After completing a specific course at an authorised training centre, they continue their training here, on the job.’

Take an EV battery from a passenger car, for instance. It is a long way from a small common-or-garden battery. Geert Allard: ‘No two batteries that come into Bebat are alike. The position in the vehicle varies, too. But these days, the battery is often in the floor of the vehicle and is the size of a wooden pallet. These batteries are usually screwed on underneath the car in a sturdy casing: a protective metal case that prevents water, dust or soil getting into the battery.’

dismantle EV battery

Risk factors and how to avoid them

EV batteries have to be dismantled carefully. There are a number of risk factors to take into account:

  • Overheating
  • Fire
  • Gassing (some gases are toxic)
  • Instability (extinguishing is sometimes complicated due to the risk of reignition)
  • Short circuit
  • Explosion
  • Electrocution

Sometimes specific guidelines from the customer or the brand have to be taken into account, too. Dismantling is always customised work for Bebat. Each job is different, and what the customer wants is decisive. 


Dismantling is always customised work for Bebat. Each job is different, and what the customer wants is decisive

Opening the casing

The protective case around the battery is unscrewed and adhesive and silicones are removed. There are often also electrical components and cables for liquid coolants (cooling) or air (ventilation) that have to be taken away.

Voltage measurements

These are taken before and during the dismantling process. The modules/cells are gradually removed from the battery pack in order to reduce the voltage for safe processing. Ultimately, all the cells are removed.

Temperature measurements

Besides the voltage, the temperature is also measured by means of a heat scan. If this rises above the ambient temperature, it is an indication that something is amiss. Cells that show no deviation from the ambient temperature can be safely stored.

After dismantling

Once the battery has been dismantled, the battery cells are packed up again and - if necessary - stored in a specially secured area that is constantly monitored, among other things. From there they are taken to a recognised recycling company. 

What exactly does the recycling of EV batteries involve?

  • Diagnosis, collection and transport
  • Dismantling of battery pack and module
  • Recycling (pyrometallurgical, mechanical, hydrometallurgical and hybrid, etc.): raw materials are retrieved using all sorts of techniques.
  • Refining the raw materials retrieved

What will mobility look like in 2030?

Which new batteries are on their way and how will we be able to process them even more efficiently in the future? Read all about it in Bebat's latest e-book.

Download it here for free  

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