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arxiv: 2605.18183 · v1 · pith:JRQV36PInew · submitted 2026-05-18 · ❄️ cond-mat.mtrl-sci

Characterisation of fire-damaged batteries,implications for recycling

Wafaa AlShatty (1) (2) , Tom Dunlop (2) , Rhys Charles (2) , Davide Deganello (2) , Jenny Baker (1)(2) This is my paper

Pith reviewed 2026-05-20 09:37 UTC · model grok-4.3

classification ❄️ cond-mat.mtrl-sci
keywords lithium-ion batteriesfire-damaged wasteNMC811battery recyclingparticle size distributionblack massmetal recoverycurrent collectors
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The pith

Fire-damaged NMC811 batteries fragment into fine particles where cobalt, manganese and nickel concentrate, but this friability mixes in more copper and aluminium and lowers recycling output quality if mixed with normal black mass.

A machine-rendered reading of the paper's core claim, the machinery that carries it, and where it could break.

The paper examines how fire damage changes the makeup of waste from NMC811 lithium-ion batteries and what that means for recovering valuable metals. It finds that nickel-, manganese- and cobalt-rich particles gather mainly in the smallest size fractions under 125 microns, reaching up to 85 percent of the metal content, and that fire-damaged waste follows the same pattern though less strongly. The damaged material breaks apart easily into fines, carrying extra current-collector metals with it and creating inconsistent composition when fed into standard black-mass lines. The authors therefore recommend processing fire-damaged batteries on separate lines or using size-based separation so that high-value NMC811 material stays concentrated and outputs remain consistent for buyers.

Core claim

Cobalt-, manganese- and nickel-rich NMC811 particles concentrate in the smaller than 125-micron fractions of both normal black mass and fire-damaged waste, accounting for up to 85 percent of total metal content in those fines; fire-damaged material shows evidence of structural breakdown from temperatures above 500 °C yet retains residual organic binders, indicating uneven heating, and becomes friable so that it fragments readily and carries higher levels of copper and aluminium current-collector pieces into the processed fines, thereby introducing variability that reduces the concentration of high-value NMC811 when the two waste streams are combined.

What carries the argument

Particle-size fractionation combined with the increased friability of fire-damaged battery material, which governs where NMC811 particles and current-collector metals end up after fragmentation.

Load-bearing premise

The fire-damaged samples examined are representative of the particle-size distributions, degradation patterns and binder residues that arise in real recycling-facility fires.

What would settle it

A side-by-side measurement of final metal concentrations and current-collector contamination levels from a working recycling plant that processes mixed black mass plus fire-damaged waste versus the same plant running fire-damaged waste on a dedicated size-sorted stream.

Figures

Figures reproduced from arXiv: 2605.18183 by Davide Deganello (2), Jenny Baker (1)(2), Rhys Charles (2), Tom Dunlop (2), Wafaa AlShatty (1) (2).

Figure 1
Figure 1. Figure 1: Photograph of analysed samples: a. as received FD sampleb. as received BM c. >300 µm FD fraction; d. 125-300 µm FD fraction; e.<125 µm FD fraction; f. >300 µm BM fraction; g.125-300 µm BM fraction; and h. <125 µm BM fraction. Figure 2a shows the XRD spectra of the sized fractions of BM. The NMC811 structure is observed at all particle sizes, although at a lower peak intensity in the larger particle sizes. … view at source ↗
Figure 2
Figure 2. Figure 2: a shows the XRD spectra of the sized fractions of BM. The NMC811 structure is observed at all particle sizes, although at a lower peak intensity in the larger particle sizes. This result is mirrored by the MP-AES results ( [PITH_FULL_IMAGE:figures/full_fig_p003_2.png] view at source ↗
Figure 3
Figure 3. Figure 3: SEM images of BM at three fractions (a-c), (>300 µm, 125–300 µm, and <125 µm), and (d-f) of FD (>300 µm, 125– 300 µm, and <125 µm). This data was acquired by the SU3900 Variable Pressure Scanning Electron Microscope [PITH_FULL_IMAGE:figures/full_fig_p005_3.png] view at source ↗
Figure 4
Figure 4. Figure 4: Raman shift of sized fractions of a. BM and b. FD material. The TGA profile of the BM sample exhibits two weight loss steps (Figure 5a and [PITH_FULL_IMAGE:figures/full_fig_p006_4.png] view at source ↗
Figure 5
Figure 5. Figure 5: Thermal analysis in air: a. TGA of BM, b. TGA of FD, c. derivative of TGA BM, d. derivative of TGA FD. At 10°C/1000°C, at a flow rate of 100 ml/min. Average of the three repeats [PITH_FULL_IMAGE:figures/full_fig_p006_5.png] view at source ↗
Figure 6
Figure 6. Figure 6: Thermal XRD pattern (RT, 500°C, 600°C, 900°C, [PITH_FULL_IMAGE:figures/full_fig_p007_6.png] view at source ↗
Figure 7
Figure 7. Figure 7: SEM images of BM and FD material after thermal XRD (25°C to 900°C and cooled to laboratory temperature) in an air atmosphere at three fractions (> 300, 125-300, and < 125 µm) (a, b, c) BM, and (d, e, f) FD. This data was acquired by JSM￾7800F SEM. Taken together, the thermal XRD results of the BM and FD materials indicate that the supplied NMC811 fire-damaged feedstock underwent significant thermal alterat… view at source ↗
read the original abstract

As lithium-ion battery demand grows, so do fire safety challenges. Despite this, research on fire-damaged batteries remains limited. This study explores the distribution of valuable metals (such as Ni, Mn, Co, Cu) in two types of waste derived from lithium-ion nickel-manganese-cobalt oxide batteries (NMC811), black mass (BM) and fire-damaged waste (FD). It emphasizes that cobalt, manganese, and nickel-rich NMC811 particles are predominantly found in smaller particle size fractions (<125 microns), where they can account for up to 85 percent of total metal content. Fire-damaged (FD) batteries show a similar, though less pronounced, trend. Evidence of structural degradation suggests that fire temperatures exceeded 500{\deg}C; however, the presence of residual organic binders indicates that heat was unevenly distributed during the fire. FD batteries become friable and easily fragment into fine particles, which can hinder the effective separation of copper and aluminium current collectors, increasing their presence in processed material. The inclusion of FD batteries in standard BM processing introduces variability in output composition, potentially lowering the concentration of high-value NMC811 materials present. To maintain product quality and recycling output values, it is recommended that FD batteries are processed separately. Alternatively, particle size separation may allow for tailored outputs aligned with specific customer requirements.

Editorial analysis

A structured set of objections, weighed in public.

Desk editor's note, referee report, simulated authors' rebuttal, and a circularity audit. Tearing a paper down is the easy half of reading it; the pith above is the substance, this is the friction.

Referee Report

3 major / 3 minor

Summary. This paper characterizes the distribution of valuable metals in black mass and fire-damaged waste from NMC811 lithium-ion batteries. Key findings include the enrichment of cobalt, manganese, and nickel in smaller particle size fractions (<125 microns), accounting for up to 85% of total metal content, with a similar but less pronounced trend in fire-damaged samples. It provides evidence of structural degradation indicating temperatures above 500°C with uneven heat distribution, and notes that fire-damaged batteries are friable, which can hinder separation of current collectors. The authors recommend separate processing of fire-damaged batteries to maintain recycling quality.

Significance. Should the central observations on size-dependent metal enrichment and the friability of fire-damaged material prove representative, this study would offer valuable insights for improving lithium-ion battery recycling processes. It addresses an emerging challenge in the field by linking fire damage to processing difficulties and suggests practical strategies like size separation to optimize outputs. The empirical approach provides concrete data that could guide industry practices in handling increasing volumes of fire-affected battery waste.

major comments (3)
  1. [Materials and Methods] The manuscript does not report the number of fire-damaged samples studied or any replicates. This is critical because the representativeness of the observed particle size distributions and residual binder evidence for general fire events is a load-bearing assumption for the recycling recommendations.
  2. [Results and Discussion] The 85% metal content figure for NMC811 in <125 μm fractions is presented without error bars, sample counts, or statistical analysis, as highlighted by the lack of quantitative methods in the abstract. This weakens the verifiability of the size-dependent enrichment claim.
  3. [Implications] The suggestion that FD batteries should be processed separately assumes that the friability and increased fine particle generation are characteristic of FD batteries broadly, but without temperature-time data or controlled comparisons, this risks being specific to the sampled waste streams rather than a general finding.
minor comments (3)
  1. [Title] The title contains a typographical error with a missing space after the comma: 'batteries,implications'.
  2. [Abstract] Include at least a brief description of the characterization techniques employed and the number of samples to provide context for the reported percentages.
  3. [Figures/Tables] Particle size distribution data should be accompanied by clear indications of variability or number of measurements to enhance clarity.

Simulated Author's Rebuttal

3 responses · 1 unresolved

We thank the referee for their thoughtful and constructive review. We have prepared point-by-point responses to the major comments and will revise the manuscript accordingly to improve clarity, transparency, and the framing of our conclusions.

read point-by-point responses

  1. Referee: [Materials and Methods] The manuscript does not report the number of fire-damaged samples studied or any replicates. This is critical because the representativeness of the observed particle size distributions and residual binder evidence for general fire events is a load-bearing assumption for the recycling recommendations.

    Authors: We agree that explicit reporting of sample numbers and replicates is necessary. In the revised manuscript we will add a dedicated paragraph in Materials and Methods stating that the fire-damaged waste originated from a single documented incident involving multiple NMC811 packs and that all particle-size and compositional measurements were performed on three independent subsamples drawn from the processed material. We will also note that the study is presented as a detailed characterisation of this specific waste stream rather than a statistically powered survey of all possible fire events. revision: yes

  2. Referee: [Results and Discussion] The 85% metal content figure for NMC811 in <125 μm fractions is presented without error bars, sample counts, or statistical analysis, as highlighted by the lack of quantitative methods in the abstract. This weakens the verifiability of the size-dependent enrichment claim.

    Authors: The 85 % figure is the cumulative proportion of Ni, Mn and Co recovered in the <125 μm fraction relative to the total metal inventory across all size fractions. We will revise both the abstract and Results section to report the underlying sample counts (three subsamples) and to include standard deviations from replicate ICP-OES analyses as error bars on the size-fraction histograms. We will also add a short methods paragraph describing the quantitative workflow. Because the material is heterogeneous industrial waste, we will describe the data as observed distributions rather than claiming formal statistical inference across multiple independent fires. revision: yes

  3. Referee: [Implications] The suggestion that FD batteries should be processed separately assumes that the friability and increased fine particle generation are characteristic of FD batteries broadly, but without temperature-time data or controlled comparisons, this risks being specific to the sampled waste streams rather than a general finding.

    Authors: We accept that the absence of temperature-time histories and controlled laboratory burns limits the ability to generalise. In the revised Implications section we will explicitly label the work as a case study of post-incident recycling waste, retain the practical recommendation for separate handling on the basis of the observed friability and current-collector contamination, and add a sentence calling for future controlled experiments to test broader applicability. The structural evidence (phase changes consistent with >500 °C together with residual binder) remains valid for the sampled material and supports the quality-control argument we advance. revision: partial

standing simulated objections not resolved
  • Temperature-time profiles and controlled laboratory fire comparisons are unavailable because the samples are real-world post-incident waste rather than experimentally burned batteries.

Circularity Check

0 steps flagged

No circularity: pure empirical characterization of physical samples

full rationale

The paper reports direct measurements of particle size fractions, metal concentrations (Ni, Mn, Co, Cu), structural degradation, and binder residues from two specific waste streams (black mass and fire-damaged material). No equations, fitted parameters, predictive models, or derivations are present. All claims rest on laboratory observations of the sampled material rather than any self-referential loop, self-citation chain, or renaming of inputs as outputs. The analysis is therefore self-contained against external benchmarks.

Axiom & Free-Parameter Ledger

0 free parameters · 0 axioms · 0 invented entities

No free parameters, mathematical axioms, or postulated entities; the work rests entirely on direct laboratory measurements of real battery waste samples.

pith-pipeline@v0.9.0 · 5798 in / 1204 out tokens · 41164 ms · 2026-05-20T09:37:40.318732+00:00 · methodology

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