Periodic Reporting for period 1 - GR4FITE3 (Graphite Resilience For lithium-Ion baTtery anodes through a sustainable European End-to-End supply chain)
Reporting period: 2023-05-01 to 2024-10-31
The GR4FITE3 project aims to establish a fully sustainable and economically viable graphite supply chain in Europe to support the growing demand for battery-grade graphite, driven by the electric vehicle (EV) and energy storage sectors. The project focuses on enhancing the European supply chain by integrating both natural and recycled graphite, improving processing methods, and contributing to environmental sustainability and energy security in line with EU goals. One of the primary objectives is to build a complete European graphite supply chain, beginning with the Zavalievsky Mine in Ukraine and extending to the integration of hybridized graphite materials in lithium-ion battery anodes. This will help reduce Europe’s reliance on graphite imports. The project will also scale up production at the Zavalievsky Mine, aiming to meet about 10% of Europe’s projected 2030 graphite demand, thus strengthening Europe’s energy security. In addition, the project focuses on advancing recycling methods by recovering and reusing synthetic graphite from spent lithium-ion batteries, contributing to a circular economy for graphite. A key innovation is the development of an environmentally responsible purification process that avoids hydrofluoric acid while achieving a carbon purity of at least 99.95% for natural graphite.
The project will also work on producing high-performance spherical carbon-coated graphite for use in EV batteries and developing innovative hybridized anode materials by combining natural and recycled graphite with nanosized silicon. Optimizing binder compositions for hybridized anodes will ensure better performance and longevity. Further objectives include creating prototype lithium-ion battery cells for testing and performance qualification, as well as conducting a life cycle analysis to reduce the carbon footprint of graphite production to 0.5 kg CO2eq/kg, significantly lowering environmental impact. Overall, the GR4FITE3 project will reduce Europe’s dependency on graphite imports, enhance energy security, and boost the competitiveness of Europe’s battery industry. It will foster circular economy practices, improve recycling rates, reduce CO2 emissions, and position Europe as a leader in the global battery supply chain, all while contributing to the EU's energy transition and sustainability objectives.
The project will also work on producing high-performance spherical carbon-coated graphite for use in EV batteries and developing innovative hybridized anode materials by combining natural and recycled graphite with nanosized silicon. Optimizing binder compositions for hybridized anodes will ensure better performance and longevity. Further objectives include creating prototype lithium-ion battery cells for testing and performance qualification, as well as conducting a life cycle analysis to reduce the carbon footprint of graphite production to 0.5 kg CO2eq/kg, significantly lowering environmental impact. Overall, the GR4FITE3 project will reduce Europe’s dependency on graphite imports, enhance energy security, and boost the competitiveness of Europe’s battery industry. It will foster circular economy practices, improve recycling rates, reduce CO2 emissions, and position Europe as a leader in the global battery supply chain, all while contributing to the EU's energy transition and sustainability objectives.
The GR4FITE3 project continues to make steady progress across its work packages, tackling challenges and advancing towards its goals.
In WP2, the focus remains on developing a cost-effective chemical purification process for graphite. Significant strides have been made, achieving a high purity of 99.99%. However, delays have arisen due to a shortage of spheronized graphite needed for downstream activities like coating. Efforts are being directed towards resolving shipping issues and enhancing communication between partners to streamline these processes.
WP3 has achieved significant progress in lab-scale spheronization, thermal purification through reactor construction, and coating processes, utilizing the purified graphite supplied by WP2. While the initial results are encouraging, the team is now focusing on scaling up these methods to meet pilot production requirements. Additionally, composite anode testing remains an integral part of these ongoing efforts.
Progress in WP4 includes successful electrode fabrication using reference materials, showcasing encouraging initial results. Standardization of electrods preparation is underway, with plans to scale up roll-to-roll coating activities. The availability of materials from WP2 and WP3 remains a critical factor for further progress in this area.
In WP5, scale-up activities are advancing, with the goal of benchmarking the materials against industrial standards. A key challenge here is the limited supply of spheronized graphite, prompting the exploration of subcontracting solutions to meet production demands.
WP6 is making strides in sustainability, particularly in the recovery of graphite from spent batteries. These efforts are complemented by ongoing environmental and social impact assessments, which aim to address variability in recycled materials by adopting blending strategies to ensure consistency and quality.
Finally, WP7 has been focused on dissemination and engagement. The next project newsletter is in preparation, and work is ongoing to boost online visibility and stakeholder involvement. Contributions from project partners remain critical to achieving these communication goals.
Overall, the GR4FITE3 project is navigating challenges effectively while maintaining progress across its interconnected work packages, with a strong emphasis on collaboration and innovation to drive the initiative forward.
In WP2, the focus remains on developing a cost-effective chemical purification process for graphite. Significant strides have been made, achieving a high purity of 99.99%. However, delays have arisen due to a shortage of spheronized graphite needed for downstream activities like coating. Efforts are being directed towards resolving shipping issues and enhancing communication between partners to streamline these processes.
WP3 has achieved significant progress in lab-scale spheronization, thermal purification through reactor construction, and coating processes, utilizing the purified graphite supplied by WP2. While the initial results are encouraging, the team is now focusing on scaling up these methods to meet pilot production requirements. Additionally, composite anode testing remains an integral part of these ongoing efforts.
Progress in WP4 includes successful electrode fabrication using reference materials, showcasing encouraging initial results. Standardization of electrods preparation is underway, with plans to scale up roll-to-roll coating activities. The availability of materials from WP2 and WP3 remains a critical factor for further progress in this area.
In WP5, scale-up activities are advancing, with the goal of benchmarking the materials against industrial standards. A key challenge here is the limited supply of spheronized graphite, prompting the exploration of subcontracting solutions to meet production demands.
WP6 is making strides in sustainability, particularly in the recovery of graphite from spent batteries. These efforts are complemented by ongoing environmental and social impact assessments, which aim to address variability in recycled materials by adopting blending strategies to ensure consistency and quality.
Finally, WP7 has been focused on dissemination and engagement. The next project newsletter is in preparation, and work is ongoing to boost online visibility and stakeholder involvement. Contributions from project partners remain critical to achieving these communication goals.
Overall, the GR4FITE3 project is navigating challenges effectively while maintaining progress across its interconnected work packages, with a strong emphasis on collaboration and innovation to drive the initiative forward.
-Reduce the dependence of European OEMs on Asian suppliers of raw materials specific to graphite, anodes, and batteries
-3D geological and thermal structure model
-Recovering, repairing, and reusing unit of synthetic graphite from spent lithium-ion batteries
-Zero-HF Chemical Purification Unit to obtain a minimum purity level of 99.95 wt.% carbon
-Low Cost & Highly Efficient Sustainable Thermal Purification Unit
-Spheroidisation unit of hybridized composite particles composed in-situ of primary natural recycled synthetic graphite with some addition of nanosized silicon or silicon oxide
-Innovative Gas-Fired Reactor capable of curing nano-scale coatings based on water-based Carbon pitch
-High Calendared Density Anode production/ Cell Production / Form-factored pack assembly design for specific use of targeted OEMs of GR4FITE3’s anode material
-New LCA insights incl. recycled graphite supply chain
-3D geological and thermal structure model
-Recovering, repairing, and reusing unit of synthetic graphite from spent lithium-ion batteries
-Zero-HF Chemical Purification Unit to obtain a minimum purity level of 99.95 wt.% carbon
-Low Cost & Highly Efficient Sustainable Thermal Purification Unit
-Spheroidisation unit of hybridized composite particles composed in-situ of primary natural recycled synthetic graphite with some addition of nanosized silicon or silicon oxide
-Innovative Gas-Fired Reactor capable of curing nano-scale coatings based on water-based Carbon pitch
-High Calendared Density Anode production/ Cell Production / Form-factored pack assembly design for specific use of targeted OEMs of GR4FITE3’s anode material
-New LCA insights incl. recycled graphite supply chain