Fraunhofer Institute for Integrated Circuits IIS
Fraunhofer Institute for Integrated Circuits IIS
© Fraunhofer IIS/ Paul Pulkert

DangerSort – Sustainable and safe

© Fraunhofer IIS/ Paul Pulkert

DangerSort: Intelligent AI sorting for the early detection of lithium-ion batteries in waste streams

© Fraunhofer IIS/ Paul Pulkert
The industrial prototype of DangerSort was completed at the end of 2024.

DangerSort is an integrated sorting solution installed upstream of industrial waste treatment plants which uses AI-based sorting to detect and remove hazardous objects – in particular lithium-ion batteries – at an early stage. The system addresses the increasing fire risks in sorting facilities resulting from the growing number of batteries in waste. Using a high‑throughput X‑ray system and AI‑based image analysis, DangerSort identifies batteries even when they are hidden in dense, multi‑layer material streams. By selectively removing them using pneumatic valves, safety in sorting and recycling facilities is significantly increased.

Fields of application

  • Early detection of hazardous objects (especially lithium-ion batteries) in waste streams
  • Pre-sorting upstream of industrial sorting and recycling lines
  • Increasing safety in sorting facilities by reducing fire risk
  • Testing and further development of AI detection models under real operating conditions
© Fraunhofer IIS/ Paul Pulkert
Interior view of the system during waste sorting.

Specifications

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Position in process Installed upstream of industrial waste treatment plants
Material throughput Up to approx. 15 t/h
Conveyor belt speed Approx. 2–3.5 m/s
Sensor principle Transmission X-ray system, optimized for high industrial throughput
Voxel size / spatial resolution Approx. 0.4 mm
Image frequency Up to 7,500 Hz
Tube voltage Up to 160 kV
Material flow Uses X-ray imaging even with dense, non-monolayer material flows
Object spectrum Large, heterogeneous objects; no fine shredding required
AI evaluation Deep neural networks based on YOLO-type architectures, adapted to X-ray data and further developed with field data
Ejection High-speed pneumatic valves with limited carry-over of surrounding material
Operation Designed for continuous operation in demanding industrial environments
Components Uses industry-proven X-ray and plant technology; maintenance-friendly

Design and operation

DangerSort consists of a high‑resolution transmission X‑ray sensor, an AI‑based analysis system, and a pneumatic ejection module. The X-ray sensor continuously generates high-resolution, high-frequency images of dense, multi-layer waste streams, which are evaluated in real time by deep neural networks. The AI, based on adapted YOLO architectures, interprets the internal structure of the objects and identifies batteries, in particular lithium‑ion batteries, as especially critical hazards. When such an object is located, high‑speed pneumatic valves control targeted ejection, removing only a small amount of surrounding material. The architecture is designed for high throughput and robust, long-term operation and can be integrated into existing sorting lines.

At a glance

  • Reliable early detection of lithium-ion batteries in complex waste streams
  • Real-time analysis by AI models adapted to X-ray data (YOLO type)
    High throughput: up to approx. 15 t/h at approx. 2–3.5 m/s conveyor speed
  • Transmission X-ray with high resolution (around 0.4 mm), high image frequency (up to 7,500 Hz) and up to 160 kV
  • Penetrates dense, non-monolayer material layers and handles large, heterogeneous objects without fine shredding
  • Targeted ejection via high-speed pneumatic valves with minimal disruption of the main material flow
  • Use of industry-proven components, continuous operation and maintenance-friendly design
  • Industrial prototype completed at the end of 2024; in practical testing since spring 2025 at a Lobbe site in eastern Germany

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