Periodic Reporting for period 1 - RECIRCULATE (Reuse of batteries through characterisation, smart logistics, automated pack and module dismantling and repackaging and a blockchain enabled marketplace.)
Reporting period: 2023-05-01 to 2024-10-31
Global battery demand is expected to surge from 282GWh in 2020 to ~2,623GWh by 2030, posing sustainability challenges. The RECIRCULATE project addresses this by extending battery lifespans through innovative reuse strategies, enabling second- and third-life applications to maximize value and reduce costs per kWh. By promoting a circular economy, the project minimizes waste, reduces the need for new resources, and supports the EU's goal of cutting greenhouse gas emissions by 55% by 2030, driving decarbonization and resource efficiency.
The project aims to address key challenges hindering broad battery reuse:
• Limited Lifespan & High Disposal Rates: Lack of reliable methods to assess and extend battery life leads to premature disposal and wasted potential.
• Safety Risks: Improper handling, transport, and reuse pose risks like fires, chemical leaks, and explosions.
• Inefficient Sorting & Characterization: Current technologies are slow, unreliable, and insufficient for circular economy demands.
• Fragmented Supply Chains: Inconsistent data and processes disrupt the efficient transfer of batteries across life cycles.
RECIRCULATE focuses on six key pillars to address battery challenges and promote sustainability:
• Fast and Accurate Sorting: Developing rapid technologies to categorize batteries by type, chemistry, and condition for efficient reuse or recycling.
• Safe Storage and Transportation: Creating smart logistics solutions to ensure the safe handling and transport of batteries.
• SoX Characterization: Implementing reliable, cost-effective methods to assess battery health and maximize their use.
• Automated Dismantling: Using AI-driven robotized systems for safe, efficient battery disassembly, reducing risks and speeding up processes.
• Repair, Reuse, and Remanufacture: Facilitating battery repair and refurbishment to extend lifespans and minimize waste.
• Blockchain Battery Passport and Marketplace: Establishing a digital platform to track, trade, and manage batteries transparently and efficiently within the circular economy.
RECIRCULATE will contribute towards a number of EU initiatives particularly in economic & green
growth:
-2020 Circular Economy Action Plan which has the aim of making sustainable products the norm
in the EU.
-European Green Deal that aims that batteries are more sustainable throughout their life cycle.
-The project addresses the three core objectives of the European Growth Model which are based on moving towards a resilient, green and digital economy. These will bring multiple benefits to the EU across the environment, health, security of supply and economy.
The project will assess social impacts using UNEP's Social LCA Guidelines, focusing on human rights, working conditions, and sustainability across the global value chain. Key socio-economic issues addressed include:
1. Cost barriers: Reducing dismantling/recycling costs to improve battery access for poorer communities.
2. Mining impacts: Mitigating social and environmental harms of primary resource mining through reuse, recycling, and secure supply chains.
3. Battery waste: Developing sustainable dismantling/recycling methods and educating stakeholders to promote adoption of battery technologies.
RECIRCULATE is powered by a consortium of 11 partners from 8 countries, combining the strengths of tech startups, academia, and industry leaders to drive forward the future of sustainable battery use. The partnership is led by Finnish University of Applied Sciences Centria, and the other 10 partners are: Probot (Finland), CSEM (Switzerland), Libattion (Switzerland), Eurecat (Spain), ECOSTOR (Norway), Ford-Otosan((Turkey), DHL (Turkey), GelKoh (Germany), Minespider (Germany) and Iconiq Innovation (UK).
The project aims to address key challenges hindering broad battery reuse:
• Limited Lifespan & High Disposal Rates: Lack of reliable methods to assess and extend battery life leads to premature disposal and wasted potential.
• Safety Risks: Improper handling, transport, and reuse pose risks like fires, chemical leaks, and explosions.
• Inefficient Sorting & Characterization: Current technologies are slow, unreliable, and insufficient for circular economy demands.
• Fragmented Supply Chains: Inconsistent data and processes disrupt the efficient transfer of batteries across life cycles.
RECIRCULATE focuses on six key pillars to address battery challenges and promote sustainability:
• Fast and Accurate Sorting: Developing rapid technologies to categorize batteries by type, chemistry, and condition for efficient reuse or recycling.
• Safe Storage and Transportation: Creating smart logistics solutions to ensure the safe handling and transport of batteries.
• SoX Characterization: Implementing reliable, cost-effective methods to assess battery health and maximize their use.
• Automated Dismantling: Using AI-driven robotized systems for safe, efficient battery disassembly, reducing risks and speeding up processes.
• Repair, Reuse, and Remanufacture: Facilitating battery repair and refurbishment to extend lifespans and minimize waste.
• Blockchain Battery Passport and Marketplace: Establishing a digital platform to track, trade, and manage batteries transparently and efficiently within the circular economy.
RECIRCULATE will contribute towards a number of EU initiatives particularly in economic & green
growth:
-2020 Circular Economy Action Plan which has the aim of making sustainable products the norm
in the EU.
-European Green Deal that aims that batteries are more sustainable throughout their life cycle.
-The project addresses the three core objectives of the European Growth Model which are based on moving towards a resilient, green and digital economy. These will bring multiple benefits to the EU across the environment, health, security of supply and economy.
The project will assess social impacts using UNEP's Social LCA Guidelines, focusing on human rights, working conditions, and sustainability across the global value chain. Key socio-economic issues addressed include:
1. Cost barriers: Reducing dismantling/recycling costs to improve battery access for poorer communities.
2. Mining impacts: Mitigating social and environmental harms of primary resource mining through reuse, recycling, and secure supply chains.
3. Battery waste: Developing sustainable dismantling/recycling methods and educating stakeholders to promote adoption of battery technologies.
RECIRCULATE is powered by a consortium of 11 partners from 8 countries, combining the strengths of tech startups, academia, and industry leaders to drive forward the future of sustainable battery use. The partnership is led by Finnish University of Applied Sciences Centria, and the other 10 partners are: Probot (Finland), CSEM (Switzerland), Libattion (Switzerland), Eurecat (Spain), ECOSTOR (Norway), Ford-Otosan((Turkey), DHL (Turkey), GelKoh (Germany), Minespider (Germany) and Iconiq Innovation (UK).
RECIRCULATE’s first 18 months has gone roughly to plan, yielding many interesting and important results on which to build in the coming years. A brief outline of the headline developments follows:
• Module and Cell SoX Characterization: it was evaluated cell-level SoH and it was started module-level replication.
• Module and Cell SoS Characterization: Developed ML algorithm for real-time SoH and SoS prediction with high accuracy.
• Battery Transport and Storage System: Initial transportation system designed with IoT-enabled DigiTruck tested on two vehicles.
• AI-Based robotic dismantling and sorting (D&S) system: Specifications and best practices documented in Deliverable D2.1.
• Ongoing work to demonstrate an AI-Based robotic D&S: Pack-to-module level robotic system with AI developed.
• Battery Passport Templates and Workflows: First iteration completed.
• Digital Battery Passports (DBP) and Blockchain Marketplace: DBP first iteration completed; and the MVP of the Marketplace MVP.
• Environmental and Social Impact Analysis: Baseline LCA completed; and the scenario data collection is ongoing.
• Advanced zBMS Development: Cell-level testing operational, module-level upscaling in progress.
• HiL Methodologies for Grid Discharge: SoX protocol is being tuned using open-source data.
• Module and Cell SoX Characterization: it was evaluated cell-level SoH and it was started module-level replication.
• Module and Cell SoS Characterization: Developed ML algorithm for real-time SoH and SoS prediction with high accuracy.
• Battery Transport and Storage System: Initial transportation system designed with IoT-enabled DigiTruck tested on two vehicles.
• AI-Based robotic dismantling and sorting (D&S) system: Specifications and best practices documented in Deliverable D2.1.
• Ongoing work to demonstrate an AI-Based robotic D&S: Pack-to-module level robotic system with AI developed.
• Battery Passport Templates and Workflows: First iteration completed.
• Digital Battery Passports (DBP) and Blockchain Marketplace: DBP first iteration completed; and the MVP of the Marketplace MVP.
• Environmental and Social Impact Analysis: Baseline LCA completed; and the scenario data collection is ongoing.
• Advanced zBMS Development: Cell-level testing operational, module-level upscaling in progress.
• HiL Methodologies for Grid Discharge: SoX protocol is being tuned using open-source data.
The current status and interim achievements of the RECIRCULATE project representing advancements beyond the state-of-the-art are as follows:
- Assessment Protocols & Equipment for SoC, SoH, and SoS: Rapid SoX assessment protocol developed and tested with datasets (physical models and open-source DB). EIS-based protocols are operational at the cell level.
- Validated AI-Backed Control Process for Automated Dismantling: Pack-to-module dismantling robot is operational at lab-level. The integration of developed component detection ML models with the high-level controller is ongoing. The virtual training factory utilizing the implemented digital models is available online.
- BMS for Second-Life Applications: Reliability improvements in EIS and communication has been achieved. Updates to be incorporated into the Battery management system (BMS) during the 2nd project period.
- Process Definition for Sorting by SoX and Battery Provenance: SoX algorithms being tuned for cell and pack levels. The BMS and CAN interface have been utilized for extracting SoX information.
- Smart/Safe Shipping and Storage Solutions for Second-Life Batteries: DigiTruck IoT concept largely completed; preliminary studies conducted. CAD design finished and first mock-up in production.
- Blockchain-Backed Marketplace Prototype: Marketplace prototype (MVP) developed and implemented in a test environment.
- Assessment Protocols & Equipment for SoC, SoH, and SoS: Rapid SoX assessment protocol developed and tested with datasets (physical models and open-source DB). EIS-based protocols are operational at the cell level.
- Validated AI-Backed Control Process for Automated Dismantling: Pack-to-module dismantling robot is operational at lab-level. The integration of developed component detection ML models with the high-level controller is ongoing. The virtual training factory utilizing the implemented digital models is available online.
- BMS for Second-Life Applications: Reliability improvements in EIS and communication has been achieved. Updates to be incorporated into the Battery management system (BMS) during the 2nd project period.
- Process Definition for Sorting by SoX and Battery Provenance: SoX algorithms being tuned for cell and pack levels. The BMS and CAN interface have been utilized for extracting SoX information.
- Smart/Safe Shipping and Storage Solutions for Second-Life Batteries: DigiTruck IoT concept largely completed; preliminary studies conducted. CAD design finished and first mock-up in production.
- Blockchain-Backed Marketplace Prototype: Marketplace prototype (MVP) developed and implemented in a test environment.