End-of-life and battery recycling

Batteries are a key factor for the implementation of the energy transition. To ensure a sustainable approach, a holistic view of battery technologies is necessary. In this context, the limited use of critical raw materials, a design which is suitable for dismantling and recycling, second-life models, and intelligent, resource-saving, and efficient recycling are crucial. Process can be optimized through digitized preparation of accompanying information for track and trace concepts. Circular economy measures help to significantly reduce the CO₂ footprint of batteries.

The member institutes have many years of experience in the evaluation of battery and process technologies along the entire value chain from raw material extraction to the battery and recycling. Current lithium-ion batteries as well as future lithium-sulfur batteries and redox-flow batteries are considered, as well as emerging technologies such as solid-state batteries. Already during the development of new battery technologies and the optimization of existing systems, the amount of critical raw materials as well as a recycling-friendly design of the cells and modules are taken into account. Life cycle analysis (LCA) focuses on the areas of cell production (cradle-to-gate), second-use (cradle-to-cradle) and recycling (cradle-to-grave), which are supported by appropriate software and data bases. In the context of second-use concepts for aged lithium-ion batteries, one focus of the institutes is on the industrial reconditioning of modules. For this purpose, methods of rapid characterization are applied and classified second-life batteries are equipped with electrical and optical sensor safety systems in ordeer to archieve reliable and long-term operation in the non-linear aging phase.

The activities in battery recycling range from mechanical pretreatment and preparation to material recycling (hydrometallurgical and electrochemical processes) to the recovery of functional materials from the black mass and electrolytes as well as regeneration of active materials and the investigation of the reusability of recycled active materials. The focus is on the resource-saving, efficent and innovative process management, which can also be transferred to the recycling of future technologies such as solid-state batteries. Recycling is accompanied by comprehensive analysis of the materials, characterization methods and process monitoring. In addition, processes for the automatic disassembly and reassembly of battery systems and their subcomponents are also being considered. Furthermore to the design of respective factory and logistics systems, this includes in particular the development of automated testing, disassembly and reassembly functionalities and their linking to flexible process chains.