PyroGenesis Advances Plasma Technology in Battery Recycling Trials

PyroGenesis Plasma Torch   Photo Credit: PyroGenesis

PyroGenesis Inc. said it has completed a primary testing campaign with a large-scale battery recycler, marking a step forward in efforts to replace fossil-fuel-based heating with electric plasma systems in lithium-ion battery processing. The Montreal-based company disclosed the results in a corporate update, confirming that initial trials met performance expectations under a previously announced agreement.

The tests evaluated PyroGenesis’ high-temperature plasma torch technology within the client’s material recovery and battery production workflow. Engineers from the recycling company observed the campaign at PyroGenesis’ facilities. Material samples have since been shipped to the client for independent verification of yield, chemistry and process performance metrics, the company said.

The collaboration was first announced in December 2025 with a targeted testing window spanning the fourth quarter of 2025 through the first quarter of 2026. With the initial phase now complete, a second round of trials may be conducted before the end of the second quarter of 2026 if required. Any further development would precede potential commercial deployment.

PyroGenesis indicated that the recycler’s long-term objective could involve purchasing an initial 1-megawatt plasma torch system, followed by either five additional 1-MW units or a single 5-MW system. The client has also signaled possible demand for multiple 5-MW systems. The company cautioned that no purchase commitments have been finalized and further testing decisions remain pending.

The project centers on using plasma to superheat battery materials during recycling, particularly in the recovery of cathode and anode components containing nickel, cobalt, copper and lithium compounds. Conventional recycling operations often rely on natural gas or other fossil-fuel-based heat sources. Analysts note that electrified thermal processes could reduce direct emissions and align recyclers with tightening decarbonization targets across North America and Europe.

The announcement comes as battery recycling capacity expands globally in anticipation of rising end-of-life volumes. Industry forecasts cited by market researchers project used lithium-ion battery volumes could grow from roughly 900,000 metric tons in 2025 to more than 20 million tons by 2040, reflecting rapid electric vehicle adoption and stationary storage deployment. Observers say scaling efficient, lower-emission recovery systems will be critical to securing secondary supplies of battery-grade materials and mitigating reliance on newly mined resources.

Plasma-based systems offer high energy density and precise temperature control, attributes that could improve material separation and metal recovery rates. However, industry groups caution that commercial viability will depend on operating costs, system durability and integration within existing hydrometallurgical or mechanical processing lines.

In a statement accompanying the results, President and CEO P. Peter Pascali said the tests demonstrate plasma’s potential role in shifting the sector toward full lifecycle battery management. He added that electrified recovery processes could help manufacturers reduce exposure to commodity price volatility and supply chain disruptions while lowering emissions.

If subsequent validation confirms scalability and economic performance, the technology could represent an incremental step toward electrified, closed-loop battery recycling systems. For now, the project remains in its evaluation stage, with commercialization contingent on further testing outcomes and capital commitments.

Source: PyroGenesis

SUNSHINE Spotlight: PyroGenesis’ successful plasma trials highlight growing industry interest in electrified, lower-emission solutions for scaling lithium-ion battery recycling.