Workstream 4: Recycling and Sustainability

This WS aims to develop and offer highly efficient recycling solutions in compliance with sustainability and life-cycle assessments for batteries in terms of tracking, collecting and dismantling of LIBs and post-LIBs until recovering of relevant metals. Therefore, the aim is to develop a process that ensures a circular material flow making battery cell manufacturers more independent from critical raw materials. Furthermore, the sustainability is checked in the context of ethics and human rights, especially for the mining of raw materials. Traceability activities within this WS aim to convert this current state-of-the-art into asset by generating mechanisms favouring sustainable raw material production. Solutions and certification schemes for traceability should enable verifying the chain of custody, location and history of an item by documented identification.

In particular, new developments of batteries must be examined for their recyclability. The developments of new materials and prototypes must be tested for recyclability theoretically and practically. Changed chemistry and structure leads to changed recyclability and suitability of existing recycling processes and waste management systems. These activities must be coordinated and integrated with the other WS. The end-of-life considerations should already be integrated into the planning process of the recycling plant construction.

This WS will also address the development of systems that foster the circular economy and the re-use of the batteries for other second-life applications different from the ones they were devised for. Furthermore, the developments of either communication protocols which facilitate second life re-use channels or sustainable BMS design for extra vehicular applications such as Pack to Grid and Vehicle to Grid are addressed.

Another focus is the construction of suitable and safe unloading, testing and disassembly infrastructure in the form of pilot plants. In this context, the development of the required processes, test routines and standardization is significant.

As a result of this WS, new, first-in-kind collection, dismantling, repurposing, recycling and refining processes will be developed, allowing to effectively recycle LIBs, HBS, ultracapacitors and other waste containing metals important for e-mobility.

IPCEI Partner

Austrian Institute for Technology: AIT

Associated Partner

Austria

Borealis

Direct Partner

Austria

Cenate

Associated Partner

Cenate is a company developing and manufacturing next generation silicon based anode materials for use in lithium-ion batteries, mainly for the rapidly growing EV battery market. By replacing graphite with our silicon nanocomposite materials, the battery energy density and the EV driving range increase significantly, and the carbon emissions from production are nearly eliminated. The company has a pilot plant at Tomter (near Oslo, Norway) and research/HQ office in Oslo.

Norway

In the IPCEI project, Cenate will develop its innovative production processes for the initial product to industrial maturity in the first Giga scale silicon anode materials plant on the European continent – delivering thereafter a 3 GWh/year supply capacity to the European EV industry and building a platform for subsequent rapid growth. The project will also include further product development, including a new product suitable for a silicon dominant anode, where most of the graphite in the anode is replaced with silicon. Lastly, the project will include development of a product with so long lifetime that it can possibly be used in buses and trucks – and thereby also be suitable for recycling in the passenger EV market.

www.cenate.com   

CeNTI

Associated Partner

CeNTI – Centre for Nanotechnology and Advanced Materials is a private, non-profit Centre for Technology and Innovation with a multi-sectoral and multidisciplinary orientation, equipped with cutting-edge technology since 2006.

CeNTI develops Research and Development (R&D) activities for industrial endogenization, product engineering, and technology transfer of disruptive technologies to companies, in the fields of Nanotechnology, Advanced Materials and Smart Systems. 

Portugal

With a robust portfolio of projects, at both national and international level, CeNTI also plays a vital role in transferring knowledge across sectors, including automotive, aeronautics, construction, health, and energy. The new disruptive technologies are focused on sustainable solutions, bioeconomy, energy decarbonization, and digital transformation of materials and processes.

In the area of advanced battery solutions, CeNTI providing support throughout the entire battery value chain, from lab research to pilot-scale development. This includes: i) extraction and refining for the development of active materials and by-products valorisation; ii) development of battery components like cathodes, anodes, and separators and cell assembly; iii) smart sensors and advanced battery management systems for mobility and stationary storage applications, and iv) testing, second life applications, recycling, and recovery of critical raw materials at end-of-life.

Project Description

Within the IPCEI project, we will develop a streamlined process to advance sustainable battery technologies from concept to pilot-scale production. Key activities include developing cost-effective anodes using low-purity silicon, as well as scaling up the slurry mixing process with advanced and sustainable active materials. These components will be tested and validated in the pouch cell assembly line. Additionally, we will explore methods to recover these materials, emphasizing eco-friendly practices and sustainability, with a focus on recyclability to support a circular economy.

https://www.centi.pt/

ENEA

Associated Partner

ENEA is the National Agency for New Technologies, Energy and Sustainable Economic Development, a public body aimed at research, technological innovation, and the provision of advanced services to businesses, public administration, and citizens. His sectors of interest are energy technologies (renewable sources, energy storage, smart grids).

Italy

ENEA's primary objective will be to develop electrochemically active materials, characterized by greater capacity and efficiency. Not only is the activity aimed at creating lighter and longer-lasting systems, but also to find solutions that are safe for users and for the environment and fundamentally cheaper than current storage technologies. Additionally, the Advanced Battery Laboratory (AB-Lab) will be built to assist the industry. The AB-LAb is conceived as a flexible and multipurpose platform where it is possible to carry out the entire production process for the creation of newly developed batteries, optimized end-of-life management, and innovative recycling.

https://www.enea.it/en/

Enel X

Direct Partner

Enel X, Enel Group’s global business line, is a leader in the energy sector, offering services that accelerate innovation and boost the energy transition.

Italy

Through its advanced solutions, Enel X provides each partner with an ecosystem of tech platforms and consulting services, focusing on sustainability and circular economy principles in order to provide an alternative model that respects the environment and integrates technological innovation into daily life. Each solution has the power to turn decarbonization, electrification and digitalization goals into sustainable actions for everyone.

Description of the projects

Enel X is proposing 3 projects:
•    High Power Chargers for EVs with Battery Storage, with innovative and flexible architecture also for providing grid services, and with some sites equipped with second life batteries
•    Advanced SW for optimally managing Battery Energy Storage systems, also applied to second life batteries,
•    Recycling of EV and stationary batteries: R&D&I activities on advanced automatization,  optimization of processes, definition of best practice for optimally managing exhausted batteries

www.enelx.com

ENGITEC

Direct Partner

ENGITEC Technologies S.p.A. is an engineering and contracting company designing and building plants based on its own technologies and processes mainly in the field of non-ferrous metals and is qualified to build small, mid-sized and large industrial plants in-house, from the definition of technology to erection and start-up.

Italy

The company’s research and development activity has resulted in development and implementation of unique technologies for recycling and transformation of highly polluting and dangerous wastes.
“Inspiring Innovation” is the key Company Mission of ENGITEC, which is pursued daily by developing recycling technologies to enable efficiency and environmental compliance.

Description of the project

The Engitec project is relevant to the development of a technology for the recycling of all kinds of spent lithium batteries on the market. The project will develop, starting from the research and development phase: a first laboratory plant, a pilot plant to be operated in the facility of our IPCEI partner and to show to the stakeholders, scale-up engineering, a first industrial plant up to the construction of other industrial plants.

www.engitec.com

 

Fortum

Direct Partner

Fortum Oy is a leading clean-energy company that provides its customers with electricity, heating and cooling as well as smart solutions to improve resource efficiency and recycling.

Finland

Fortum wants to engage its customers and society at large to join the change for a cleaner world. Fortum is a LE.

The aim of the project is a first industrial deployment of a comprehensive battery recycling service concept. The project comprises the digital tools for battery state-of-healt analysis, 2nd life application, safe logistics and mechanical recycling process for end-of-life batteries. The concept maximizes the value of a battery after the first life phase and ensures the efficient recycling of the battery components.

www.fortum.com

 

Hydrometal

Direct Partner

Established for more than 30 years in Engis near Liège (Belgium), HYDROMETAL is a major recycling and recovery centre for a very wide range of materials (over 70,000t / year), by-products or complex residues containing non-ferrous metals, in particular: Zn, Ni, Cu, Pb, Sn, Co, other minor metals, precious metals and rare earths.

Belgium

Hydrometal's expertise is based on different hydrometallurgical processes, unique in the world, which consume very little energy and generate only small amounts of CO2 and ultimate waste.

Its industrial activity is strongly linked to the Zn element with the production pure Zn salts. The recycling of Co, Ni and Li is also part of its know-how.

Description of the project

Hydrometal’s project is an innovative alternative to the state-of-the-art techniques. It offers:

  • An improved and innovative full hydrometallurgical recycling process for the “black mass” coming from pre-treatment of spent Li-ion battery, that allow multi-elements recovery including lithium and graphite, that can be integrated as secondary raw materials in existing production lines.
  • An original way to recover Co that consumes less energy than pyrometallurgical processes
  • A Method to improve the global recovery yield of all the elements including F, Mn, graphite.

The project of Hydrometal allows to close the recycling loop by carrying out last step of recycling and first step of raw material production, useful for new batteries production.

www.jgi-hydrometal.be

 

 

IONCOR Oy

Direct Partner

IONCOR is a leading European provider of battery modules and battery packs for electrified vehicles. The company focuses on battery systems designed for the automotive industry, bus & truck sectors and off-highway machinery, such as construction, material handling, agriculture, mining, and forestry. 

Finland

The company offers modular battery products, customized solutions, and contract manufacturing services to drive electrification across its customer segments. IONCOR, founded in September 2019 as Valmet Automotive EV Systems business line, operates technology and battery test centers and three high-volume battery system plants in Finland and Germany.

Description of the project

With Industrial Battery Innovation Center initiative IONCOR will create and engineer equipment electrification solutions to support industrial customers with product design capabilities to successfully implement an electric drivetrain. Implementing common platforms and modularity in product design, battery production and life-cycle management will provide the systemic design approach, which will be needed to meet the requirements and customization needs of harsh use equipment manufacturers.

www.ioncor-batteries.com

 

 

Italmatch Chemicals

Direct Partner

Italmatch Chemicals is a Global Specialty Chemical Group, leader in Phosphorus Derivatives for Flame Retardants, Plastics Additives, Lubricant, Water & Oil, Detergency.

Italy

With 17 manufacturing plants worldwide (7 in Europe) and 6 excellence R&D centre, Italmatch is active in mainly 4 sectors:

  1. Performance Products: from specialty phosphorus based derivatives to fatty acid chlorides and esters. Main markets are intermediates for lithium battery electrolytes, precious metal recycling, special mining additives, agrochemicals, pharma and cosmetics
  2. Flame retardants and plastic additives: from red phosphorus to halogen free flame retardants through high spec additives. Main markets are engineering thermoplastics and polyolefins
  3. Lubricant Performance Additives: polymeric and complex esters, phosphorus pentasulfide, amides, EP additives, hydraulic fluids, grease additives and MWF additives. Main markets are intermediates, additives & components for industrial and automotive lubrication and metal working
  4. Advanced Water Solutions: from corrosion inhibitors to removing, recovery and cleaning based on the most innovative chemistry. Main markets are desalination, water treatment, geothermal, O&G, I&I and valuable metals recovery

Description of the project

PARSES aims at developing various phosphorus-based additives, to feed the battery value chain at different levels, through:

  1. WP1- LiPF6 Manufacturing Plant, the first-in-its-kind in Europe (in collaboration with Fluorsid): establishing the first-in-its-kind LiPF6 (Lithium Ion Battery electrolyte precursor) manufacturing pilot plant in Europe, to pave the road for European commercial production, fulfilling the local Li-Ion Battery needs and contribute to the European independency transition.
  2. WP2- All-Solid-State-Lithium-Batteries (ASSLBs) and All-Solid-State-Lithium-Sulphur-Batteries (ASSLSBs)   Material Development Contribution: exploring and setting up a pioneering phosphorus penta-sulphide (P2S5, solid electrolytes precursor) pilot plant in Europe, to feed the solid electrolytes producers inside and outside the Italian context with a suitable material meeting the requirements of the IPCEI  circular battery value chain.
  3. WP3- Nickel, Cobalt, Lithium and other are rare-earth elements recovery from exhausted batteries – Development of new chemistry / co-formulations for a sustainable hydrometallurgy recycling process: developing innovative IoT integrated chemical technologies towards an efficient recovery of Lithium, Cobalt  and Nickel in partnership with several intra-European participants to the initiative, in a concept of circular economy and environmental sustainability

www.italmatch.com

 

 

K1-MET

Associated Partner

K1-MET’s research work is focused on sustainable and climate-neutral metallurgy. Regarding sustainability and circular economy, the focus is on process development and product quality in ferrous and non-ferrous metallurgy as well as closing material cycles by treating and reusing by-products (dusts, slags etc.).

Austria

Decarbonization is about demonstrating industrial processes in ferrous and non-ferrous metallurgy by using hydrogen. With regards to sector coupling, the conversion of CO2 represents an important aspect (e.g., synthetic methane using hydrogen) to ensure that CO2 becomes a valuable material. Process diagnostics and advanced data analytics coupled with single- and multiphase flow simulation are the cornerstones of another research area aiming at a real-time monitoring of metallurgical processes.

FuLIBatteR stands for "Future Lithium-Ion Battery Recycling for Recovery of Critical Raw Materials" and is dedicated to sustainable recovery of critical raw materials (CRMs) and valuable metals from lithium-ion batteries (LIBs). Its primary objectives include closing the gap in material cycles, establishing an eco-friendly battery value chain, and ensuring a secure supply of raw materials. Innovative physical, pyrometallurgical and bio-hydrometallurgical treatment approaches that surpass conventional techniques will turn waste into valuable secondary raw materials embracing sustainability, reducing CO2 emissions, and driving the EU to the forefront of battery recycling.

https://www.k1-met.com/en/modul_fulibatter

Lifthium Energy

Associated Partner

Lithium Energy is a pioneering Portuguese company aiming to be at the forefront of the energy transition, currently testing a revolutionary technology centered around electrolysis to produce high-grade lithium for batteries. Lifthium's ambition is to provide sustainable and high-quality lithium hydroxide to promote energy transition and contribute to making electric mobility accessible to all.

Portugal

Lifthium believes that its innovative approach could mark a significant leap forward in sustainable lithium production, promising to reshape the landscape of the European energy transition ecosystem towards the sound establishment of electric mobility. With a planned investment of a billion euros by 2030, Lifthium aims to have two lithium refinement factories operation in Europe with a refining capacity of 50 thousand tons, intending to supply lithium hydroxide to over two million vehicles annually. As leaders in advancing clean energy technologies, Lithium Energy is poised to contribute to the global shift towards greener and more efficient battery technologies.

www.Lifthiumenergy.com 

Liofit

Direct Partner

Liofit will apply the principle of circular economy to Li-ion batteries of micro-electromobility (pedelecs, e-scooters).

Germany

These batteries will be tested, dismantled, recombined and repaired. Batteries that can no longer be reused are discharged and shredded in an environmentally friendly manner so that the raw materials can be reused. Battery and recycling know-how are brought together under one roof, thus contributing to more climate-friendly mobility. Milestones already achieved include a bicycle battery database with over 600 different types, inverter-based dischargers and various module disassembly strategies.

LITTLE ELECTRIC CAR

Direct Partner

LITTLE ELECTRIC CAR SPAIN is a manufacturer of electric vehicles, battery packs and special projects.

Spain

Born in 2008, when the first electric vehicule, the Little4, was designed by engineers from Spain, France and Portugal. Little Spain was established in 2010 as a company specialized in multidisciplinar electric vehicles: delivering, special transport, water electric karts and electrification. Now, Little offers battery packs with its innovative project “2econd life Battery Packs“.

Description of the project

Collection of batteries from differents brands and models of electric vehicules at its end of life, analysis of that batteries, classification according to their state of life and the later use in the construction of new Energy Sotorage Systems. We innovate in three aspects: Creating an automated process, Logistics 4.0, which register the traceability of all components, from scrap yards or workshops to the finished product. Create a systematized process of tests and records of the collected products and third; the development of a specific software for ESS management.

www.little-cars.es

 

Materials Center Leoben (MCL)

Associated Partner

The Materials Center Leoben (MCL) is Austria´s leading research centre in the field of materials research and process technology. The strategic objective of the MCL is to develop new expertise by initiating and supporting long-term research collaboration between science and industry in top-level research.  The general research program of MCL focuses on “Integrated Computational Materials, Process and Product Engineering”. In particular we accelerate the development of new and improved materials, parts and components for green mobility, microelectronics and energy technology.through computer-aided technologies based on high-end characterization, measurement data, physical models and artificial intelligence (AI).

Austria

The scope of the project is to foster accelerated & sustainable material- and cell-development, incorporating unique modern experimental characterization as well as computational artificial intelligence-based analysis tools on different length-scales. We provide knowledge with respect to underlying degradation mechanism on material and cell level in context to the cell performance and processing. Enhanced knowledge about the process-structure-property relationship is delivered by the MCL to boost the development of advanced and sustainable materials, innovative battery cells, and green batteries.

www.mcl.at 

Midac

Direct Partner

Midac SpA is an Italian company founded in 1989 that produces lead batteries for motive power automotive and stand-by use.

Italy

Since 2014, MIDAC SpA has started the design, development, and production of Li-ion batteries, supported by a strong investment plan in the sector. Midac Spa has two manufacturing plants in Italy (Soave VR and Cremona) and subsidiaries operating in Germany, France, UK, Ireland, Sweden, and Australia. Today Midac is among the European leaders in the production of motive power batteries.

Description of the project

Midac Spa aims the creation of a truly circular value chain regarding the manufacturing and recovery of lithium batteries. MIDAC project cover three IPCEI Work Streams:WS2, WS3 and WS4. Starting from the collection of spent LiBs, MIDAC will be sorting modules/cells for “second use” or “direct recycling”. Through the construction of a recycling plant, MIDAC will obtain raw materials to produce new cells to manufacture “First life” battery pack to be sold it in the industrial field. Using the sorted modules/cells, “second life” batteries will be manufactured to be sold in the energy storage field.

www.midacbatteries.com

 

Sibanye-Stillwater - Keliber

Direct Partner

Sibanye-Stillwater’s Keliber lithium project

Sibanye-Stillwater’s Keliber lithium project is located in Kaustinen and Kokkola, Finland, where it is currently building a concentrator and a lithium refinery. The project is expected to be the first integrated European producer of battery-grade lithium hydroxide from its own mineral reserves, and to supply the region's battery industry with a critical raw material that is necessary to produce electric vehicles.   

Finland

The Keliber lithium project is owned by Sibanye-Stillwater (79.8%), a multinational mining and metals processing Group, and Finnish Minerals Group (20%), a state-owned company developing the value chain of lithium-ion batteries in Finland.

Description of the project

Keliber lithium project’s main objective is to further develop and optimize company’s production process and secure sustainable production of high-quality lithium hydroxide fulfilling the cost, quality, and safety requirements of the customers. Novel on-line monitoring techniques are used for the process and final product quality optimization. Additionally, Sibanye Stillwater’s Keliber lithium project will increase the cooperation with participating downstream processing companies for becoming a solid part of the European lithium-ion battery value chain.

https://www.sibanyestillwater.com/business/europe/keliber/

 

TAB Tovarna Akumulatorskih Baterij d.d

Associated Partner

Slovenia

Verkor

Associated Partner

France

Vianode

Associated Partner

Vianode is an advanced battery materials company providing sustainable anode graphite solutions for the battery and EV value chains. Vianode’s breakthrough solution enables tailored high-performance synthetic anode graphite and a holistic sustainability offering including a 90% reduction in CO2 footprint. The company is currently preparing to start its customer qualification plant at Herøya, Norway, before executing its multi-billion dollar phased investment program for large-scale plants in Europe and North America. The long-term ambition is to supply advanced battery materials to 3 million EVs per year by 2030. Vianode is owned by the world-leading industrial and financial companies Elkem, Hydro and Altor.

Norway

The overall aim of project SUSAN (Center for SUStainable ANodes) is to expand the R&D activities within and across Vianode R&D facilities; the Vianode Industrial Pilot (VIP), the Vianode Technology Center (VTC) and the Vianode Customer Qualification Plant (VCQP). Within the project, the VTC and VIP will incubate innovation activities at lower TRLs whereas the VCQP will bring innovations to TRL8, as to speed up qualification processes for novel, sustainable products through cost competitive and green processes. Through this project, Vianode will build a center for excellence, innovation and knowledge sharing for the next generation, high-performing, green battery anode materials. The project will contribute strongly to the IPCEI EuBatIn Workstream 1 “Raw and Advanced Materials” and Workstream 4 “Recycling and sustainability”. Through project SUSAN, EuBatIn members will benefit from a strong innovation partner that will pro-actively contribute to shaping a clean, interconnected, and circular battery value chain built on a European technology and sustainability leadership.

https://www.vianode.com/

ZTS

Direct Partner

ZTS – VÝSKUM A VÝVOJ is a research, development, and engineering company with tradition in energy engineering, especially in water and nuclear sectors.

Slovakia

The history of research and development in the company is linked to the extensive production program of the Czechoslovak engineering group ZTS with more than 50-year tradition. Since 1997, when it has been transformed into its present form, its program has been focused on design of modernization, reconstruction, and overhaul of technological equipment of water powerplants, and design and construction documentation of equipment.

Description of the project

The project deals with the production of battery modules from used electric vehicle batteries. When the battery capacity drops below 80%, the comfort of using EV decreases due to further charging and shorter range. The batteries are becoming less suitable for further use in electromobility, however, could be used again in less dynamic applications. The project solves this problem by developing a device for the automatic regeneration of EV batteries. The product of the project is a regenerated battery module of 2nd life, with guaranteed parameters, designed for stationary use.

www.ztsvav.eu

 

Overview of the IPCEI EuBatIn Work Streams