The electric vehicle market is booming and plays a crucial role in our global climate goals. However, with this growth comes an increase in the number of consumed batteries that contain valuable raw materials. Unfortunately, there are currently no truly efficient and energy-saving recycling technologies available – there is still much work to be done!

The "ProBatman" project aims to address this issue by optimizing recycling processes and developing new technologies to improve the quality and yield of battery recycling. Various battery types, including NMC and LFP, will be examined, along with both used and defective lithium-ion batteries.

The project partners are focusing on innovative methods to open the batteries, process the electrolytes, and make the electrodes reusable. Additionally, ecological, economic, and social aspects will be considered at every step.

Key areas of focus for the Fraunhofer Institute for Silicate Research:

• De-coating of cathodes using inductive and laser-based methods
• Classification of black mass using various centrifuges and hydrocyclones
• Analysis of the de-coated electrode fragments and de-agglomerated fractions
• Regeneration of recycled cathode materials through spray drying
• Scaling of sub-processes
• Production of cathodes using recyclates and assembly of pouch cells
   

As a result of this project, several development goals are being pursued:

The aim is to develop novel methods for the de-coating of cathodes, the classification of black mass, and the regeneration of recycled cathode materials. Furthermore, new know-how in the field of direct recycling of various cell chemistries will be established to gain a better understanding of the differences in recycling production scraps and end-of-life batteries. Another goal is to assemble lithium-ion batteries that contain a high proportion of recycled material without compromising performance.