SeRoBatt: "Secondary Sources of Critical Raw Materials for Battery Cell Production - Potentials, Recovery, Resynthesis"

New approaches for sustainable battery raw materials

To advance electromobility and the energy transition, we require large quantities of critical raw materials such as lithium, nickel, and cobalt. The SeRoBatt research project is seeking innovative ways to recover these valuable materials from new sources.

 

Why is this project important?

Currently, material cycles are not closed. A considerable part of end-of-life products either end up in landfills or are exported abroad as scrap. This means that valuable raw materials are lost to the European market. At the same time, the new EU Battery Regulation is increasing pressure on manufacturers to use a certain proportion of recycled material in new batteries in the future. However, there are not enough end-of-life batteries available for the recycling market, and European recycling capacities are still in the process of being established.

 

Our approach: recycling beyond the battery

SeRoBatt focuses on products that are not batteries themselves but still contain important battery raw materials. In a circular research approach, material and material flow analyses are used to examine various EoL products containing lithium, nickel, manganese and cobalt for their suitability for battery production.

Particular focus is placed on glass ceramics, which represent the second largest group of lithium-containing products after lithium-ion batteries and for which there is currently no regulated material cycle.

An ecological and economic assessment is being used to examine the extent to which the recovery of these raw materials makes sense from these perspectives. All steps along the value chain are also being considered, from collection and dismantling to pre-treatment and recovery to resynthesis. The aim is to analyse the ecological and economic viability of a circular business model. The results are summarised in a ‘secondary raw materials map’, which also provides information on transferability to other material flows, optimisation potential and regulatory gaps.

© Fraunhofer IWKS
Members of the SeRoBatt project team visit modular sorting plant at Fraunhofer IWKS Alzenau
© Fraunhofer IWKS
Intensive mixer filled with grinding balls
© Fraunhofer IWKS
Relevant components of mechanochemical lithium recycling: grinding balls, glass ceramics and sodium hydroxide

Project schedule

The work plan is divided into eight steps:

  1. identification of significant EoL products through material and material flow analysis
  2. procurement, dismantling and characterization of the selected material flows as input for mechanical processing
  3. preparation of the EoL products for the lithium and NMC recovery processes by developing and testing product-specific mechanical processing concepts
  4. lithium is recovered as lithium carbonate from Li-containing glass-ceramic powder
  5. recovery of NMC materials through process development and implementation
  6. evaluation of industrial transferability with regard to ecological and economic aspects
  7. use of recyclates in active material synthesis and cell construction. Derivation of quality requirements for the metal salts and the production of new lithium-ion batteries by identifying a sensible proportion of recycled material
  8. recording significant research results for industrial purposes