Research and development of a highly automated and safe streamlined process for increased Lithium-ion battery repurposing and recycling

Project Information

REBELION

Grant agreement ID: 101104241

DOI

10.3030/101104241

EC signature date 21 April 2023

Start date 1 June 2023

End date 30 November 2026

Funded under

• Climate, Energy and Mobility

Total cost

€ 3 764 298,75

EU contribution

€ 3 764 298,50

Coordinated by

UNIVERSITAT POLITECNICA DE VALENCIA
Spain

Periodic Reporting for period 1 - REBELION (Research and development of a highly automated and safe streamlined process for increased Lithium-ion battery repurposing and recycling)

Reporting period: 2023-06-01 to 2024-11-30

Summary of the context and overall objectives of the project

The drive towards clean energy, electric vehicles, and battery-dependent machinery highlights the emerging battery waste issue. By 2040, this could result in a significant problem, with an estimated 9 million tonnes annually. Unfortunately, many used lithium-ion batteries suitable for second-life use are being discarded, missing recycling and automated dismantling opportunities. The EU-funded REBELION project aims to address the challenges hindering the increased reuse, recycling, and dismantling of lithium-ion batteries. To enhance the second-life utility of batteries, the project will introduce fast battery testing, improved labelling facilitated by digital technologies, and enhanced safety systems. Importantly, REBELION will explore automated dismantling, currently a costly and dangerous manual process. This research will determine whether efficient recycling and second-life use can become profitable through cost-effective automation.
The increasing e-mobility will trigger a battery waste problem (9Mtons/year by 2040) despite that many of the used LIBs are suited for 2nd-life applications for an additional 10 years, representing an opportunity to diminish energy and raw materials dependencies in Europe.
Technical hurdles are preventing the re-use and recycling of Li-ion batteries. Besides the heterogeneity of the battery stock, assessing their condition for further usage is a slow process performed with equipment not suited for industrial contexts while. Dismantling packs and modules is in addition a costly and slow manual process because its automation faces extremely complex, multi-scale, cluttered and densely packed environments.

REBELION will validate two circular schemes (including Light e-vehicles) to maximise 2nd life utility and domestic applications, enabled by a disruptive fast battery testing based on Electronic Noise Analysis, and an autonomous pack and module disassembly system with re-configuring capabilities for the ongoing battery types and formats. Additionally, a novel labelling system supported with blockchain, digital battery passport and ecolabel technology will provide key information to dismantlers, recyclers, re-manufacturers and users.

Processing large volumes of used batteries increases the risks of thermal runway incidents, requiring thus novel safety protocols and systems. REBELION will add thermal monitoring and the design of a smart container for storage and transportation with thermal and gas sensing layers to monitor the limiting oxygen index and lower explosive limits, and a cooling system that activates when thresholds are surpassed.

REBELION consortium covers all the value chain, including advanced robotic line and car manufacturer, bringing key knowledge, proprietary technology, and pilot validation facilities. The combination of five research centres and seven industrial partners will ensure technology transference from lab to industrial context.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The initial 18 months of the REBELION project have been dedicated to establishing the foundations of the project requirements and to the development of the individual technologies that we aim to validate in the second half of the project in an integrated manner (see figure above).addressing the recycling and second-life applications of lithium-ion batteries (LIBs).
In a preliminary phase, substantial progress has been achieved, including the successful completion of WP2: Definition of Requirements. Presently, the project is transitioning into the active development of key technologies. These include the creation of ICT platforms, digital battery passports, safety protocols, thermal monitoring systems, and automated disassembly solutions, which are central to REBELION's long-term objectives. The focus during this phase is on turning these technological concepts into practical, scalable solutions. By the end of 2025, the project will enter a critical stage of integration and validation, where the technologies developed will be tested in relevant conditions, and their performance will be assessed.
Throughout this period, coordination dissemination, communication, and exploitation activities have been continuously executed, ensuring the smooth progress of the project and fostering collaboration and knowledge sharing among stakeholders. These activities, planned to span from month 1 to month 42, are key to the project's success and play an essential role in facilitating the adoption of REBELION's solutions in the market.
REBELION project is on track, and the expected outcomes remain fully achievable by the end of the project. The successful completion of the tasks in this first period, coupled with the planned integration and validation of technologies in the coming months, positions the project for continued success and significant impact in the field of battery recycling and second life applications

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Key epxloitable results will emerge in REBELION project during 2025 and 2026.
So far, we have established project requirements and started developing the technological advances.