Periodic Reporting for period 1 - FREE4LIB (FEASIBLE RECOVERY OF CRITICAL RAW MATERIALS THROUGH A NEW CIRCULAR ECOSYSTEM FOR A LI-ION BATTERY CROSS-VALUE CHAIN IN EUROPE)
Reporting period: 2022-09-01 to 2024-02-29
The FREE4LIB project aims to develop and scale technologies (TRL 5-6) to achieve six new sustainable and efficient processes for recycling end-of-life (EOL) lithium-ion batteries (LIBs). The project focuses on dismantling, pre-treatment, and four material recovery processes to deliver innovative recycling solutions that ensure high material recovery efficiency for metal oxides, metals, and polymers. The objectives include improving the supply of secondary resources at the EU level, enhancing the re-use of metals and polymers, and synthesizing electrodes for greener batteries. Additionally, the project aims to implement the Battery Passport methodology to improve process traceability.
During Reporting Period 1 (RP1), significant progress was made across various work packages (WPs):
WP2: Established a digital platform for recycling LIBs and created a blockchain-based Battery Passport platform.
WP3: Focused on LIB recycling and materials re-using. The dismantling process was optimized, and several recycling techniques, including mechanical, hydromechanical, and ultrasonic delamination, achieved high material recovery efficiencies.
WP4: Initiated scaling and validation of recycling technologies. Early work on robotized dismantling and scaling up pre-treatment processes showed promising results.
WP5: Developed the digital Battery Passport concept, which includes a data model and data needs. Conducted environmental, circularity, and social impact assessments.
WP6: Established the project's visual identity, website, and social media presence. Developed a comprehensive Communication, Dissemination, and Exploitation Plan and participated in various events to promote project results.
WP2: Established a digital platform for recycling LIBs and created a blockchain-based Battery Passport platform.
WP3: Focused on LIB recycling and materials re-using. The dismantling process was optimized, and several recycling techniques, including mechanical, hydromechanical, and ultrasonic delamination, achieved high material recovery efficiencies.
WP4: Initiated scaling and validation of recycling technologies. Early work on robotized dismantling and scaling up pre-treatment processes showed promising results.
WP5: Developed the digital Battery Passport concept, which includes a data model and data needs. Conducted environmental, circularity, and social impact assessments.
WP6: Established the project's visual identity, website, and social media presence. Developed a comprehensive Communication, Dissemination, and Exploitation Plan and participated in various events to promote project results.
The FREE4LIB project has made significant strides beyond the current state of the art in the field of lithium-ion battery (LIB) recycling and material recovery. This section outlines the key technological advancements achieved by the project, categorized by specific technological breakthroughs.
• Technology 1a: Robotically-Supported Battery Pack Dismantling Process.
FREE4LIB has co-designed a robotized solution for the most critical tasks, integrating advanced robotics, vision-based workspace assessment, and dexterous robotic manipulation for unscrewing and unplugging batteries. This innovation combines automated solutions for risky tasks with human-robot cooperation for complex manipulations, significantly improving efficiency and safety.
• Technologies 2a, 2b, 2c & 2d: Pre-treatment of Battery Cells.
The project is working on the upscale of the EHF process to handle 40-50 kg/h of cell material, implementing continuous EHF processes including automated skimming and sieving, achieving a tenfold increase in processing capability. Additionally, ultrasonic delamination has been explored to enhance pre-treatment efficiency achieving >95% of material separation. On the other hand, mechanical pre-treatment has achieved also a recovery efficiency above 95%.
• Technologies 3a, 3b & 3c: Cathode Direct Recycling.
A new dismantling strategy using advanced robotics for direct cathode recycling has been developed and its investigation to use green solvents such as Natural Deep Eutectic Solvents (NADES) for real cathodes with very promising results in terms of extraction efficiency of almost 100% of lithium, 96.1% of aluminium, 100% of nickel, 100% of Mn and 100% of Co. Electrochemical and hydrothermal re-lithiation techniques are being optimised to restore cathode material performance and to study the influence of variables.
• Technologies 4a & 4b: Pyro-metallurgical and Hydrometallurgical Processes.
FREE4LIB has developed a low-temperature pyro-metallurgical process that effectively recovers lithium and other metals from end-of-life (EOL) LIBs. Additionally, a hydrometallurgical method using more eco-friendly organic acids and reducing agents has been tested, improving recovery rates while minimizing environmental impact.
• Technology 5a: Decontamination of Recovered Thermoplastics.
An innovative melt extrusion technology assisted with supercritical CO2 has been employed, which enhances the removal of contaminants and improves the mechanical performance of recycled thermoplastics, making them suitable for high-value applications.
• Technology 5b: Recycling of Thermoset Fractions.
The project has developed microwave-assisted pyrolysis, which is more energy-efficient and combined with specific catalysts, reduces the energy requirements and improves yield and quality of recycled products.
• Technology 6: Centrifugal Atomization for Al and Cu Powders.
This technology has been adapted to recycle Al and Cu from batteries, producing highly spherical powders with required compositions, and scaling up the technology for industrial applications.
• Technology 7a: Selective Laser Melting (SLM) of Al Alloys.
Research on SLM parameters for atomized powders containing impurities from battery scrap has led to the successful manufacture of new Al alloys with comparable properties to commercial alloys, enhancing the recycling rate of aluminium in battery packs.
• Technologies 8a, 8b & 8c: Electrode Synthesis.
FREE4LIB has demonstrated the use of recycled metal oxides precursors to develop NMC and LMNO powders through stable and reproducible routes. Specifically, hydrothermal synthesis and Flame Spray Pyrolysis (FSP) have shown promising results for producing high-purity and homogeneous cathode materials.
• Technology 9a: Coating and Ion Implantation of Electrodes.
The project has developed new coatings based on metallic oxides using plasma-vacuum deposition techniques. Additionally, innovative plasma technology combined with Metal Vapor Vacuum Arc (MEVVA) ion implantation enhances the performance and longevity of recycled electrodes.
• State of Health (SoH) Estimation Methods.
A new SoH estimation method that combines physical and data-driven models have been assessed and implemented. This tool, designed for reuse applications, will be provided a significantly advancing SoH assessment technology.
• Battery Passport.
FREE4LIB has developed a working prototype of a battery passport that securely processes both static and dynamic battery data. This prototype aims to support sustainable and circular battery management throughout the battery's lifecycle in an Open Platform Access.
These technological advancements position FREE4LIB at the forefront of sustainable LIB recycling, significantly contributing to the circular economy and reducing the environmental impact of battery production.
• Technology 1a: Robotically-Supported Battery Pack Dismantling Process.
FREE4LIB has co-designed a robotized solution for the most critical tasks, integrating advanced robotics, vision-based workspace assessment, and dexterous robotic manipulation for unscrewing and unplugging batteries. This innovation combines automated solutions for risky tasks with human-robot cooperation for complex manipulations, significantly improving efficiency and safety.
• Technologies 2a, 2b, 2c & 2d: Pre-treatment of Battery Cells.
The project is working on the upscale of the EHF process to handle 40-50 kg/h of cell material, implementing continuous EHF processes including automated skimming and sieving, achieving a tenfold increase in processing capability. Additionally, ultrasonic delamination has been explored to enhance pre-treatment efficiency achieving >95% of material separation. On the other hand, mechanical pre-treatment has achieved also a recovery efficiency above 95%.
• Technologies 3a, 3b & 3c: Cathode Direct Recycling.
A new dismantling strategy using advanced robotics for direct cathode recycling has been developed and its investigation to use green solvents such as Natural Deep Eutectic Solvents (NADES) for real cathodes with very promising results in terms of extraction efficiency of almost 100% of lithium, 96.1% of aluminium, 100% of nickel, 100% of Mn and 100% of Co. Electrochemical and hydrothermal re-lithiation techniques are being optimised to restore cathode material performance and to study the influence of variables.
• Technologies 4a & 4b: Pyro-metallurgical and Hydrometallurgical Processes.
FREE4LIB has developed a low-temperature pyro-metallurgical process that effectively recovers lithium and other metals from end-of-life (EOL) LIBs. Additionally, a hydrometallurgical method using more eco-friendly organic acids and reducing agents has been tested, improving recovery rates while minimizing environmental impact.
• Technology 5a: Decontamination of Recovered Thermoplastics.
An innovative melt extrusion technology assisted with supercritical CO2 has been employed, which enhances the removal of contaminants and improves the mechanical performance of recycled thermoplastics, making them suitable for high-value applications.
• Technology 5b: Recycling of Thermoset Fractions.
The project has developed microwave-assisted pyrolysis, which is more energy-efficient and combined with specific catalysts, reduces the energy requirements and improves yield and quality of recycled products.
• Technology 6: Centrifugal Atomization for Al and Cu Powders.
This technology has been adapted to recycle Al and Cu from batteries, producing highly spherical powders with required compositions, and scaling up the technology for industrial applications.
• Technology 7a: Selective Laser Melting (SLM) of Al Alloys.
Research on SLM parameters for atomized powders containing impurities from battery scrap has led to the successful manufacture of new Al alloys with comparable properties to commercial alloys, enhancing the recycling rate of aluminium in battery packs.
• Technologies 8a, 8b & 8c: Electrode Synthesis.
FREE4LIB has demonstrated the use of recycled metal oxides precursors to develop NMC and LMNO powders through stable and reproducible routes. Specifically, hydrothermal synthesis and Flame Spray Pyrolysis (FSP) have shown promising results for producing high-purity and homogeneous cathode materials.
• Technology 9a: Coating and Ion Implantation of Electrodes.
The project has developed new coatings based on metallic oxides using plasma-vacuum deposition techniques. Additionally, innovative plasma technology combined with Metal Vapor Vacuum Arc (MEVVA) ion implantation enhances the performance and longevity of recycled electrodes.
• State of Health (SoH) Estimation Methods.
A new SoH estimation method that combines physical and data-driven models have been assessed and implemented. This tool, designed for reuse applications, will be provided a significantly advancing SoH assessment technology.
• Battery Passport.
FREE4LIB has developed a working prototype of a battery passport that securely processes both static and dynamic battery data. This prototype aims to support sustainable and circular battery management throughout the battery's lifecycle in an Open Platform Access.
These technological advancements position FREE4LIB at the forefront of sustainable LIB recycling, significantly contributing to the circular economy and reducing the environmental impact of battery production.