Trusted Partner in Battery Recycling
Battery recycling is becoming a cornerstone of the energy transition, with demand for lithium, cobalt, nickel, and other critical materials growing rapidly. At the center of this process is black mass—a valuable mixture of active materials recovered from spent batteries. Handling and processing this material requires precision-engineered systems for dust control, thermal treatment, and material handling.
IAC is a trusted EPC and OEM partner for battery recycling facilities, bringing over 35 years of experience in designing, fabricating, and constructing turnkey process systems. From emissions compliance and black mass drying to pneumatic conveying and automated controls, we deliver complete, integrated solutions that maximize material recovery, ensure safe operations, and scale with the industry’s future growth
Industry Challenges
Battery recycling facilities face a unique set of operational, environmental, and safety challenges. Black mass, while highly valuable, is difficult to process due to its fine particle size, hazardous content, and volatility. Facilities must manage these complexities while staying compliant and maintaining high recovery rates.
Key challenges include:
- Safe handling of hazardous materials such as lithium, lead, and electrolytes
- Containing explosive and toxic dusts to protect workers and the environment
- Meeting stringent emissions standards set by EPA, OSHA, and NESHAP regulations
- Maximizing recovery of critical metals without excessive downtime or material loss
- Designing flexible systems that can scale with the rapid growth of recycling demand
IAC’s proven experience across metals, recycling, and energy industries enables us to anticipate these challenges and deliver systems engineered for safety, compliance, and efficiency.
Core Capabilities for Battery Recycling
IAC provides a full suite of engineered solutions designed to meet the demanding requirements of black mass recovery and battery recycling operations. Our vertically integrated approach allows us to deliver custom systems that balance safety, compliance, and performance.
Air Pollution Control Systems
- High-efficiency baghouses and cyclones engineered for ultra-fine particulate capture, including graphite, carbon, lithium, cobalt, and nickel dust.
- NFPA-compliant systems with explosion venting and sealed transfer-point ventilation to manage combustible, reactive, and conductive powders.
- Integrated DSI and gas-conditioning solutions for HF, HCl, SO₂, and other acid gases released during thermal decomposition.
Thermal Processing
- Direct and indirect rotary drying and calcining systems designed for black mass moisture removal, binder burnout, and thermal decomposition.
- Customizable flighting and drum configurations for consistent heat transfer across variable black mass particle sizes.
- Integrated off-gas handling and APC tie-in to control VOCs, particulates, and acid gases generated during thermal steps.
- Low-temperature drying options for sensitive chemistries or solvent removal
Material Handling
- Belt, screw, and bucket conveyors engineered for high-load, high-wear service
- Pneumatic conveying systems in dense and dilute phase configurations
- Bulk storage silos, domes, and automated truck/rail loadout systems
Automated Controls
- MCCs and PLC-based systems for integrated plant automation
- Remote monitoring and diagnostics to maximize uptime and throughput
- NFPA-compliant designs with explosion mitigation for combustible dust environments
Industrial Construction
- Full turnkey EPC delivery, including engineering, fabrication, installation, commissioning, and project management.
- Adelphi Construction self-performs civil, mechanical, electrical, and structural scopes to accelerate schedules and reduce contractor overlap.
- Fast-track execution for new recycling lines, thermal systems, ventilation upgrades, and material handling expansions.
- 3D modeling, QA/QC workflows, and integrated controls/MCC installation to ensure system performance and rapid startup.
These capabilities ensure that IAC customers have access to end-to-end solutions, from engineered design through commissioning and long-term support.
Solutions for Battery Recycling Segments
IAC delivers specialized solutions tailored to the unique processes within the battery recycling industry. Our systems are designed for safety, compliance, and recovery efficiency, whether you are processing lithium-ion, lead-acid, or emerging chemistries.
- Lithium-Ion Battery Recycling: Black mass drying, conveying, and emissions control systems engineered to safely handle volatile fine powders and recover valuable metals such as lithium, cobalt, and nickel.
- Lead-Acid Battery Recycling: Proven dust collection technologies and safe material handling systems to manage lead exposure and ensure compliance with OSHA and NESHAP standards.
- Critical Minerals Recovery: Turnkey process systems that maximize recovery of lithium, cobalt, manganese, and other essential materials critical to supply chain resilience.
- Secondary Metals Recycling: Experience supporting smelting and refining operations, with integrated emissions control and bulk material handling solutions.
These solutions enable facilities to streamline recovery, improve worker safety, and remain in full compliance while adapting to new technologies and chemistries entering the market.
Engineering, Procurement & Construction (EPC)
IAC provides complete EPC services for battery recycling plants, from concept through commissioning. By integrating engineering, equipment manufacturing, construction, and project management under one roof, we deliver efficient, compliant, and scalable facilities.
Our EPC capabilities include:
- Turnkey plant design and build for new recycling facilities and black mass recovery lines
- Fast-track project execution to meet aggressive market timelines and capacity expansions
- Integrated engineering teams across civil, mechanical, electrical, and process disciplines
- OEM manufacturing of baghouses, dryers, conveying systems, and controls for seamless integration
- Construction services through Adelphi Construction, our wholly owned subsidiary, ensuring field execution stays aligned with design
With IAC as a single-source partner, recycling operators reduce risk, eliminate vendor conflicts, and accelerate time to market.
Field Services & Aftermarket Support
IAC supports battery recycling plants well beyond initial construction, ensuring long-term efficiency, safety, and compliance. Our lifecycle services help facilities maximize uptime, extend equipment life, and adapt to evolving process requirements.
Maintenance & Repair Services
- Scheduled bag change-outs, cage replacements, and leak testing for all baghouse brands
- Mechanical repairs including valve, damper, and fan replacement
- Equipment conversions to upgrade older reverse-air or shaker systems to modern pulse-jet technology
Training
- On-site or virtual seminars covering baghouse operation, troubleshooting, and maintenance scheduling
- Hands-on instruction from experienced IAC engineers to extend equipment life and avoid unplanned downtime
System Optimization
- Burner tuning and dryer flighting analysis to improve efficiency
- Airflow balancing and ductwork inspections to reduce emissions and wear
- Dust control retrofits for improved compliance and product recovery
Parts & Components
- 55,000+ stocked parts for baghouses, dryers, conveying systems, and controls
- Rapid shipment from strategically located warehouses to minimize downtime
- OEM and compatible parts available for multi-brand systems
Partnering with IAC
Battery recycling and black mass recovery demand precision, compliance, and speed to market. IAC brings the scale, experience, and reliability required to meet these demands while delivering measurable value.
Reasons to partner with IAC include:
- Proven expertise with over 35 years as an EPC and OEM serving recycling, metals, and energy industries
- Top 5 baghouse OEM worldwide, with more than 7,500 units in service across diverse applications
- Extensive track record in emissions control, thermal processing, and materials handling for hazardous and high-value processes
- Single-source accountability, eliminating vendor overlap by combining engineering, fabrication, construction, and service under one roof
- Trusted by major industrial clients in recycling, power generation, and secondary metals processing
With IAC, operators gain a partner focused on safety, performance, and long-term plant reliability.
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Frequently Asked Questions
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