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Sorting batteries: the Sortbat sorting system

Different battery types require different recycling processes. This means that after collection, batteries must go through a sorting process to separate out the various key chemical types. In Belgium this is done at the Sortbat facility, a branch of Bebat, and it results in 7 output streams:  

  • Alkaline and zinc-carbon batteries

    Common household batteries used in smaller devices such as remotes, toys and clocks.

  • Lithium primary

    Often used in toys and implanted medical electronic devices such as pacemakers due to their longevity, energy density and high voltage output. 

  • Lithium rechargeable

    Rechargeable lithium-ion batteries used in phones, laptops and EVs.

  • Nickel cadmium

    Durable rechargeable batteries used in older camera equipment, specific medical devices and emergency lighting.

  • Nickel metal hydride

    Durable and low-cost rechargeable batteries used in power tools, cameras, and other portable electronics. 

  • Lead-acid batteries

    Heavy batteries used in vehicles - going from car ignition systems to boats - and backup power systems.

  • Button cells

    Small coin batteries used in watches, digital thermometers, hearing aids,...

The sorting process

At the Sortbat facility, collected batteries pass through a three-step sorting process. By combining manual handling with mechanical and advanced automated techniques, batteries are gradually separated into clearly defined streams, ready for safe and efficient recycling. 

Step 1: presorting

Batteries usually arrive at the sorting facility in drums. They are unloaded onto a conveyor using a small crane. Along this conveyor belt, the batteries are first presorted by hand. Any pieces of waste are removed. If any bags (filled with batteries) appear on the belt, they are cut open in order to be able to sort the batteries in these bags as well.  

Sometimes unexpected items such as cans, food scraps, or nappies end up in the stream, which are also taken out. A system is being developed to automatically detect non-conforming items and log photos for monitoring. 

Battery packs are immediately grouped into six categories based on their chemical composition: built-in batteries in devices or rechargeable lithium, alkaline, lead, NiMH, and NiCd packs. 

Manuele-sortering

Step 2: Mechanical sorting

The batteries move along a vibrating platform with grids of increasing size, which separates them into different fractions based on their size. The smallest items are separated first: button cells and small residual material, along with vermiculite. This fraction does not continue through the next sorting steps but is immediately properly disposed of and recycled. 

Next, individual batteries are separated from battery packs. The sieve is designed to do this efficiently: individual batteries are directed to the feeding system, while battery packs are sent straight to the characterisation unit. Button cells, 4.5V, and 9V batteries are collected separately and are ready for recycling. 

Bebat_sorting_mechanical-sorting

Step 3: Feed

After the mechanical sorting, the individual batteries and battery packs are transported via separate feeding channels to the singulator, which arranges them into a single row.

From the singulator, the batteries are forwarded to the characterisation unit for further sorting.

Feed

Step 4: Automated Sorting with AI- Characterisation

The final and most advanced step in the sorting process uses artificial intelligence (AI) and X-ray technology. As the number of battery-powered devices and battery types increases, sorting becomes increasingly complex. Some batteries may have identical dimensions but different chemical compositions, making it more difficult to sort and separate them from each other. In particular, the growing variety within Li-ion chemistries adds an extra layer of complexity.

Thanks to a combination of artificial intelligence (AI) and X-ray scanning, the characterisation unit accurately identifies all household battery types, even if they are corroded. Lasers and X-ray scans identify each battery based on its chemical composition: from cylindrical batteries to battery packs, this automated system classifies batteries by chemistry, such as lithium, alkaline, zinc-carbon and more. 

AI

Once identified, each battery is automatically directed into the correct collection container according to its chemistry, ready for safe, compliant and traceable recycling.  

This technology enhances safety, reduces costs and sets a new industry standard for battery sorting.

  • The AI-based system can accurately sort deformed, corroded, or otherwise damaged batteries, even if their appearance or weight is misleading. 
  • This ensures that batteries are identified and separated based on their actual contents, improving the purity of the recycling streams. 

Sortbat also dismantles larger batteries and is always looking into new second-life uses and opportunities.

Once sorted by category, all batteries start their journey of transformation. They are sent to certified and approved recycling companies in order to be recycled.  For each category, this is done according to a specific process, whereby metals and other components are recovered and can be reused as raw materials.