Arbok-AVD (Amalgam Vacuum Distillation)

Overview

Arbok-AVD recycles lithium-ion batteries using metal amalgamation and deep-vacuum distillation instead of high-temperature smelting or acid leaching. Shredded battery metals dissolve in mercury to form an amalgam; under deep vacuum the mercury evaporates at ambient temperature and is fully recovered (closed loop), and the metals stratify by density. It processes mixed chemistries (NMC, LFP, high-nickel) at 53–88 kWh/t — up to 10× less energy than furnaces — in modular shipping-container units, replacing $100M+ furnace plants with decentralized units.

Applications

Primary use cases: EV and grid/solar storage battery recycling; end-of-life battery logistics hubs; industrial Li-ion waste.

Outputs: recovered metals, graphite, plastics, salts.

Industries and users: recyclers, EV/battery makers, waste-management and collection networks.

Scale: 10 t/module per batch; multi-module clusters.

Operating Principle

Shredded LIB material is fed to a mercury bath where metals dissolve into an amalgam; under deep vacuum the mercury evaporates at ambient temperature and is condensed back (closed loop, loss <1 %), leaving the metals to separate by density (gravity stratification). No furnace, no acid leaching.

Limitations: requires vacuum systems and engineered mercury containment; upstream shredding (50–80 kWh/t); regulatory compliance for mercury handling.

Key Parameters

Energy: 53–88 kWh/t (vs 500–1000+ kWh/t furnaces); + shredding 50–80 kWh/t. Mercury loss: <1 %.

Throughput: 10 t/module batch, with dissolution and distillation each completing within a single short batch cycle. Vacuum: deep vacuum; ambient temperature.

Form factor: standard shipping-container module; 2–3 operators/shift; service life >15 years. Chemistries: NMC, LFP, high-nickel.

Architecture and Components

Shred feed chamber; mercury bath vessel; vacuum system; condenser (mercury recovery loop); gravity stratification / collection trays; PLC control. External shredding upstream. Containerized, modular cluster of standard shipping-container units.

Advantages

Technical: ambient-temperature amalgam distillation (no 800–1500 °C furnaces); low mechanical complexity; closed-loop mercury; handles mixed chemistries.

Economic: processing cost $35–80/t vs $350–800/t industry average (market price $350–600/t); CAPEX far below $50M plants; BOOM model.

Environmental: up to 90 % less energy/ton, no combustion emissions, minimal effluent.

Strategic: decentralized, fast-scaling recycling that cuts storage-queue fire risk and capital exposure.

Integrations

Pairs with battery shredding lines, EV recycling hubs, and collection networks; feeds ARBOK metal-recovery/crystallization; ARBOK digital diagnostics.

Deployment & Operation

Steps: module delivery → install in hangar/shelter → vacuum commissioning → connect shredding feed. Semi-automated PLC, remote monitoring; add modules incrementally. Periodic vacuum/seal service.

TRL

TRL 6 (confirmed by Michael). Lab-validated with engineering prototype and controlled-environment tests; mercury-handling certification pending. Remaining: pilot deployment, industrial demonstration, and regulatory certification.

Market Potential

Battery waste is growing fast while furnace recycling is capital-heavy (5–8-year builds) and energy-intensive. A modular, low-energy, decentralized recycler fits EV, grid, and solar storage end-of-life streams worldwide.

Typical Project Economics

Processing cost $35–80/t vs $350–800/t average; market processing price $350–600/t → strong margin. CAPEX modular (≪ $50M plants); BOOM/service model; payback scales with throughput. Recovered metals/graphite add revenue.

Risk Factors

Mercury containment engineering and regulatory certification (controlled material); vacuum-system maintenance; upstream shredding dependency; conservative recycler adoption; scale-up to industrial demonstration.

Related Technologies

ARBOK-VC (Vacuum Cracking) · ARBOK-CRYSTALLIZER · ARBOK-Lithium · ARBOK-Rubidium · ARBOK-Cesium