How Do You Separate Zorba and Recover Non-Ferrous in Battery Recycling?
Updated on: 11/17/25
Are you wondering how to separate your copper and aluminum in the battery recycling process? Do you have questions about getting a pure non-ferrous fraction?
If so, you are in the right spot.
In this article, we will go over the final step in the battery recycling process and get your non-ferrous fractions separated. By the end, you will know just how to get your mixed metal stream clean and divided.
Here is a quick recap of the key stages covered in these articles so far:
- Shredding the battery – weighing the pros and cons of wet vs. dry shredding and how charge levels affect processing.
- Drying – removing residual electrolyte or water to stabilize material.
- Black mass recovery – capturing the cleanest and highest-value black mass early in the process.
- Steel removal – pulling out ferrous content using magnets.
- Delamination milling and screening – separating material into three streams: black mass, plastic separator, and zorba (copper and aluminum).
We previously highlighted the challenges of plastic separator, which binds and clogs equipment if it is not removed quickly. Now, the focus shifts to the zorba fraction and how it is further refined.
Zorba Separation: Step by Step
Once densified and milled, zorba is placed onto an air table. The table is set at a slight incline, allowing heavier particles to climb upward while lighter particles are carried off by airflow into a baghouse. This stage also helps remove residual fine plastic fragments.
From here, the zorba stream is divided into valuable fractions:
- Front side: die-cast metals, copper, and stainless steel. Even non-magnetic stainless steel becomes slightly magnetic after passing through the delamination mill, making it easier to capture with a magnet at this stage.
- Back side: small amounts of plastic mixed with densified aluminum balls. These are routed via auger to a second air table, which separates aluminum from lighter contaminants.
After the air table, the material undergoes magnetic separation to pull out stainless steel. The remaining stream is then screened using a single-deck screener:
- Oversize fraction: zinc die-cast and larger copper pieces.
- Undersize fraction: exceptionally clean copper, often reaching 98%+ purity. This high-quality copper is only achievable because the delamination mill has compressed it into small, dense balls, enabling precise downstream separation.
Tailored Systems for Different Applications
It is important to note that this process is not one-size-fits-all. Recycling strategies vary depending on whether the input is jelly rolls, cathode material, production scrap, or post-consumer batteries. While full-scale systems can handle multiple streams, tailoring the process to specific feedstock often yields significant cost savings.
Closing Thoughts
From shredding to zorba separation, this series has walked through the complete journey of battery recycling. The systematic recovery of black mass, metals, and other fractions not only maximizes material value but also ensures smoother downstream processing.
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Do you have any other questions that were not covered in this article? If so, please call Cable Management at (860) 670-1890 or click here to email us. If you are ready for equipment pricing, click here to request a quote, and a team member will be in touch shortly.
