WS #D: Repurposing, recycling and refining

In the area of repurposing, recycling and refining, the focus will be on products, materials and processes.

Regarding products, innovation will in particular consist in developing innovative battery modules housing for automotive applications designed for easy dis-assembling for lower environmental impact and better materials management and recycling.

Regarding materials, innovation will in particular consist in using, for battery housing, secondary aluminum alloys with 10 times lower carbon footprint vs. primary aluminum alloys. In addition, secondary raw materials will be turned into products and re-injected into the battery value chain.
 

Regarding processes, innovation will consist in e.g. more efficient recovery of compounds from battery scrap material which allows the achievement of highest lithium recovery at highest lithium salt purity; development of characterization methods for used batteries as well as methodologies for judging safety on used and damaged batteries for handling and transport; and flexibility regarding the type of waste (substrate) and products (e.g. metals or salts of metals);
 

IPCEI Partner

BASF

BASF creates chemistry for a sustainable future. The approximately 110,000 employees in the BASF Group work on contributing to the success of our customers in nearly all sectors and almost every country in the world.

Germany, Finland

Our portfolio is divided into six segments with eleven divisions. In addition to battery materials, BASF's Catalysts division is also responsible for our world-leading portfolio of environmental and process catalysts. BASF’s technology platform Process Research & Chemical Engineering develops new technologies and processes not only for battery research, but also for the very wide range of chemical processes.

Description of the project
E-mobility in Europe requires a locally integrated, cost-effective battery value chain that can deliver high-performance and sustainable batteries. BASF is planning a new plant for the production of cathode active materials (CAM) in Schwarzheide, Germany, which can produce cathode active materials of the latest and next generation according to innovative production processes. The project also includes intensive research activities for specific product properties and efficient recycling technology. Moreover, BASF is planning a new plant for the production of precursors (PCAM) in Harjavalta, Finland.

www.basf.com/global/de.html

Elemental Strategic Metals

Elemental Strategic Metals Sp. z o.o. is a SPV company of Elemental Holding S.A. Elemental Holding is a Poland-based, holding company active in urban mining, recycling and refining of critical raw materials focusing on battery metals, platinum group metals and precious metals.

Poland

Description of the project
Elemental Strategic Metals’ project include development in Poland of  plant for recycling of lithium-ion batteries and  other waste containing metals critical for e-mobility. The company will process various types of waste containing metals important for e-mobility, including production scrap. The recycling process will include mechanical and metallurgical treatment  leading to production of high quality raw materials for European industry.

www.elemental.biz

Endurance

Endurance SpA (Endurance), an Italy-based subsidiary of Endurance Overseas, the European holding company of the Endurance Group, active in the supply of engine and transmission components to European automotive OEMs.

Italy

Eneris

Eneris Groupa (Eneris), a Poland-based company, dedicated to innovations protecting environment (waste, water, energy) active, amongst other, in distributed energy and recycling, including batteries.

Poland

FAAM

FIB S.p.A., an Italy-based company, operating under the brand FAAM, is active in the design, production and recycling of cells, modules, and li-ion batteries for industrial, automotive, storage, and special applications.

Italy

FIB has already realized a pilot production of cells, modules, and li-ion batteries in Teverola (Italy) with a production capacity of 0.35GWh.
FIB is also active in the production and recycling of lead-acid batteries, as well as in the design and construction of plants for the recycling of end-of-life batteries.
FIB is part of Seri Industrial Group, a listed company on the Milan Stock Exchange (MTA) operating along the entire value chain of plastics (recycling, moulding, and extrusion) and batteries, that employs almost 1,000 people in 14 production plants in Italy, France, Poland, and China.

Project Description (Cells and modules WS)
The objective of the project is the design and development of beyond state-of-the-art Li-ion cells and modules, based on high-voltage, high energy, and safe active materials. Particular attention will be put on the environmental footprint, with a sustainable and efficient manufacturing process. The green manufacturing process will be carried out by eliminating toxic solvents and reducing the CO2- equivalent during production. Emphasis will be put on the battery cell and module design to be easily dismantled and recycled.
The project will be deployed in the Teverola (Italy) cluster area, where FIB is already running a 0.35GWh plant. The mission of FIB is to deploy the first Mediterranean Gigafactory.

Project Description (Recycling WS)
The objective of the project is the deployment of an industrial pilot line based on hydrometallurgical process for the recovery of the feedstock. This process, coupled with optimized logistics and integration with waste electrical and electronic equipment, will allow to reach a “zero waste” concept for the recovery of Li-ion battery materials. The collection, sorting and battery dismantling will be performed locally, based on local regulation, minimizing the transport of dangerous waste. Cell material recycling, after the deactivation and shredding, would be carried out in centralized plants, continuously fed, thus reducing energy consumption and emissions, and optimizing economics.

www.faam.com
www.seri-industrial.it

Fortum Recycling & Waste

Fortum is a European energy company providing customers with electricity, gas, heating and cooling as well as smart solutions to improve resource efficiency. Together with its subsidiary Uniper,  Fortum is the third largest producer of CO2-free electricity in Europe with activities in more than 40 countries.

Finland

Description of the projects
IPCEI on Batteries Project: Production of sustainable battery chemicals from secondary raw materials.

The objective of the project is the first industrial deployment of sustainable battery chemical production from secondary raw materials. Fortum has developed a hydrometallurgical process to recover valuable metals from secondary raw materials such as recycled battery black mass, battery material production waste and other industrial side streams. The products from the process are returned back to the battery value chain as battery chemicals.

www.fortum.com

SEEL Swedish Electric Transport Laboratory

The Swedish Electric Transport Laboratory (SEEL) is a joint venture company owned and run by Chalmers and RISE. SEEL will establish and operate a test center for research and development in the field of electromobility.

Sweden

Chalmers University of Technology in Gothenburg conducts research and education in technology and natural sciences at a high international level. RISE is an independent, state-owned group of research institutes in Sweden, which offers unique expertise and over 100 testbeds and demonstration environments for future-proof technologies, products and services.

Description of the project
The project will establish three facilities with the aim to consolidate efficient knowledge development and improve the conditions for collaboration in the field of electrified transport in Sweden and Europe. The automotive, aerospace and maritime sectors plus other developers in relevant areas will gain a common platform on which to meet, and will benefit from the knowledge development and technology shift currently taking place. Researchers will at the same time gain access to advanced research infrastructure in the field of electromobility. The test center will be operational by 2023.

www.ri.se/en/test-demo/seel

Umicore AG & Co. KG

Umicore is a materials technology company with activities in the area of recycling, catalysis and energy and surface technologies. The Umicore group has production sites over the whole world and serves customers worldwide.

Germany

In 2019 Umicore has achieved 17 Milliard (3.3 w/o metal) Euro and has been employing 11150 coworkers. Based on many years of experience in the area of metallurgy and recycling Umicore has developed and installed the worldwide first industrial recycling process for Li-Ion, Li-Polymer and NiMH batteries with high metal recovery rates.

Description of the project
The objective of the project is the development of a safe and efficient concept for the collection, transport and storage of high volumes of End-of-Life (EoL) Batteries from Hybrid and battery electric vehicles (xEVs), and also of a highly efficient battery dismantling process as important pre-step for the metallurgical recycling in a technology center for battery recycling.

This contributes to the installation of a sustainable and safe circular economy and supply of technology metals for battery materials in Europe.

www.umicore.com

Technology Fields

Overview of the the IPCEI Batteries RDI (Research, Development and Innovation) and FID (First Industrial Development) work streams