Periodic Reporting for period 1 - BatteReverse (A next-generation automated, connected, and standardised process for increased safety, efficiency, and sustainability of Li-ion BATTEry REVERSE logistics)
Reporting period: 2023-05-01 to 2024-10-31
BatteReverse aims to enable the next generation of battery reverse logistics (RL). It will develop a more efficient and universal method for battery discharge and first diagnosis for a wide range of Li-ion battery types, safety packaging with a monitoring system reducing thermal runaway risk during transportation of batteries, automated dismantling and sorting of battery components based on a safe and more efficient human-robot collaboration, and a more precise and faster Remaining Useful Life assessment of battery modules for 2nd life applications based on acoustic testing and machine learning algorithms. This will contribute to the sovereignty of the EU in the battery sector.
The Battereverse project (May 2023 – October 2026), after the first 18 months of the project, has reached main achievements. Focused on defining technical, legal, and business requirements, RUL assessment, and external insights through circular analysis, a mapping of key European industrial and legal stakeholders have been performed with the creation of a model. A list of 14 key stakeholder types were identified, and usual battery handling processes were defined too, with the objective to analyze potential risks associated to the processes. Preliminary process hazard analysis (PPHA) method was chosen. Standards and requirements (regulation (EU) 2023/1542 of the European Parliament and of the Council of 12 July 2023 on batteries and waste batteries) have been analysed. In the AIDC domain, standards and solutions in line with GS1 were recommended for identifying, marking and sharing data, using automatic identification techniques. A comprehensive data model has been proposed, aligned with other European and global initiatives for a Digital Battery Passport, and a corresponding blueprint for a system architecture to streamline data exchange during battery collection, repurposing, and recycling. Moreover, initial work has been performed on mechanisms for data governance, including mapping of information clusters and technology review. The technical and legal requirements have been firstly defined, focusing on the packaging and transportation steps. The Skoda modules characterization has been defined and partially executed, as well as the architecture and the design of the hardware and software of the DCH tools. The safe prototype transport has been designed and validated. An automated system has been developed for laboratory and industrial environments to dismantle and sort battery pack components, minimizing human exposure to the batteries and other hazardous elements, thereby reducing health risks and associated labour costs. In parallel, a hybrid battery characterization tool, based on an electrical and acoustic diagnosis battery tests combined with Machine Learning (ML)-algorithms able to merge different sorts of data, will be developed in the project, to deliver not only the battery status but also a prediction of the expected 2nd lifetime. In terms of communication, dissemination, exploitation and stakeholder engagement, the project has brought together 306 battery reverse logistics stakeholders through the BatteReverse community, sharing news (5 circular business cases, 5 Short Circuit webinars, the Battery Circularity Game, conference and webinar presentations and 1 peer-reviewed journal paper,…).
The project is developing a unified battery identification system that will connect with the Digital Battery Passport and operate through an interoperable data space. This system is expected to allow relevant stakeholders to access standardised and secure battery data. By using blockchain technology and implementing strict access policies, the system will support data integrity and traceability across the battery value chain. It is designed to align with major initiatives such as the Global Battery Passport, Battery Pass, and Catena-X, ensuring compatibility and compliance with evolving EU regulations. A dedicated tool is planned to support safe and automated battery discharge at the point of first contact in car workshops. This tool will be capable of identifying the necessary DCH parameters and discharging batteries with or without access to the Battery Management System (BMS), allowing to choose which could still be used in second-life applications. Additionally, energy recovery options will be explored and tailored to the conditions and resources available in various workshop environments. The project is developing an adaptable and connected cost-effective safety packaging solution for critically defective batteries. Battereverse is designing and testing semi-automated dismantling solutions for the two most common end-of-life scenarios: recycling and repurposing. Machine learning and advanced imaging techniques, including hyperspectroscopy and computer vision, will be explored to develop a system that automatically assesses the condition of battery components. The project also aims to standardise the logistics processes related to battery handling, including transport, dismantling, and storage..