Although safety investigations are nowadays mandatory in the industry, significant differences in the assessment of risk and hazard become apparent. These variations can be attributed to various influencing factors, such as regional legal requirements or specific industry sectors. Within the scope of a safety study at the Chair of Thermal Processing Technology, an existing test facility for carbothermal reduction (InduRed) is being systematically examined for potential hazards related to the newly planned use of black mass from lithium-ion batteries. Subsequently, the process of risk assessment according to ÖNORM 12100 is explained and methods for hazard evaluation are delineated. Following this, technical and supplementary protective measures are presented, and the individual barriers of a secure operational facility are illustrated. As a basis for the safety analysis, all available data about the pilot plant and its surroundings are collected. The subsequent steps involve determining the risk of the overall system, assessing its suitability for the use of black mass, and deriving the associated safety measures.