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.
