Fraunhofer Research Institution for Materials Recycling and Resource Strategies IWKS
Fraunhofer Research Institution for Materials Recycling and Resource Strategies IWKS

RoB@t2Cell

Batteries in the cycle: The RoB@t2Cell project – Towards sustainable and self-sufficient electric mobility

As electric mobility grows, so does the number of batteries reaching the end of their first life cycle. But what happens to them? The »RoB@t2Cell« research project is developing pioneering, automated solutions by the end of 2028 to either prepare old batteries for a second life or recycle them highly efficiently.

 

The challenge: safe handling without energy loss

So far, we have faced three key problems in dealing with end-of-life batteries, which hinder efficient recycling:

  1. The “safety dilemma”: Currently, batteries at the end of their useful life are often deep-discharged across the board to enable safe dismantling. The problem: this process often destroys the delicate internal structure of the cells, rendering them unusable for valuable second-life applications, such as stationary energy storage.
  2. The manual labour factor: Worldwide, the dismantling of batteries has so far been carried out almost exclusively by hand. Given the volumes expected in the future, this process is too slow, too expensive and not scalable.
  3. Bonded designs: Modern battery designs (such as cell-to-pack systems) are often firmly bonded or foamed, making non-destructive dismantling using conventional methods almost impossible.

The solution: an intelligent system that thinks for itself

The RoB@t2Cell project is based on an automated circular economy. At its heart is an intelligent system that tests each battery individually and decides: is it still good enough for a second life, or should it go straight to recycling?

  • Intelligent discharge: Instead of discharging batteries indiscriminately, the system tests each cell individually. Cells that are still in good condition are gently prepared for a second life; only the rest go straight to recycling.
  • Automated robotic precision: A state-of-the-art robotic cell handles the dangerous dismantling of heavy battery packs right down to the individual cell – safely, precisely and on an industrial scale.
  • Dealing with new designs: We are researching innovative methods to non-destructively separate even bonded cells and make them usable for new applications.

The contribution of Fraunhofer IWKS

Fraunhofer IWKS plays a crucial role in recovering valuable raw materials from battery cells. The experts contribute their many years of experience in the recovery of strategic materials to efficiently close the loop.

  • Innovative material separation – safe and efficient: A water-based process is being further developed, based on material-selective comminution. Thanks to these new processes, cells that are not fully discharged can also be safely processed for the first time. This drastically reduces the time required for recycling – a huge advantage for industrial scaling.
  • From module to cell – automation instead of manual labour: Together with its partner acp systems, Fraunhofer IWKS is developing a solution for the automated disassembly of battery modules down to the individual cell level. Until now, this complex task has been carried out almost exclusively by hand worldwide. With this new, robot-assisted process, we are overcoming the hurdle of time-consuming manual labour for the first time in a safe and industrially scalable manner.
  • Maximum raw material recovery: Our specialised methods enable us to recover between 95 and 98 per cent of the so-called ‘black mass’, as well as almost all metals and plastics, sorted by type. This is a crucial step towards meeting the very challenging limits set by the EU Battery Regulation.

A strong team for technological sovereignty

Under the coordination of Umicore AG & Co KG, a consortium comprising industry and research organisations (acp systems, Siemens, BorgWarner, Fraunhofer IPA, Fraunhofer IWKS and the University of Stuttgart) is working to establish an EU-wide circular economy for batteries.

© Fraunhofer IPA