22_FFG_BATTBOX - Battery recycling best operations by X processes for circular battery ecosystem

In view of the growing quantities of discarded battery systems, the development of highly automated recycling facilities will be essential in the future. However, the progressive diversification of battery systems poses major challenges for the recycling processes. A major problem is that there is currently no mandatory labelling system that provides information about the composition of lithium-ion batteries. As a result, the lack of labelling leads to impure fractions. In practice, there are three main recycling approaches - pyrometallurgical recycling - hydrometallurgical recycling - direct (mechanical) recycling Mechanical recycling in particular offers a high potential to generate a high-quality, sustainable and recyclable material stream. The research priorities planned in the BATTBOX project include technological research and plant engineering concepts that should lead to an increase in the degree of maturity in the mechanical recycling of lithium-ion battery systems. The research project aims at a multi-stage recycling process, whereby a broad spectrum of possible processes is to be developed due to the non-existing standardisations (chemistry, design, dismantlability). In each recycling process stage, a diagnosis of the exposed components is carried out with the aim of checking them for reusability according to economic and safety-critical aspects. Components that are classified as undamaged or reusable are discharged from the recycling process and not processed/dismantled any further. By splitting end-of-life components and reusable components, a significant product intensification of the original battery is achieved. High-quality and unmixed raw material fractions or components are obtained that are suitable for reuse in the production process.