Fraunhofer Research Institution for Battery Cell Production FFB 
NRW-DiRecLab
Research project, »NRW Recycling Lab for Advancing Direct Recycling Routes of Electrode Scrap from Battery Production«
In the »NRW-DiRecLab« project, the Fraunhofer FFB (Münster) and PEM (RWTH Aachen University) are establishing a research infrastructure – unique in Germany and Europe – for the direct recycling of electrode scrap from battery cell production. PEM will host a modular, flexible laboratory-scale environment, while Fraunhofer FFB will set up a scaled pilot-scale process route (vacuum comminution, supercritical CO₂ extraction, vibrating screen) plus complementary analytics and cell testing infrastructure. Five promising process routes with different delamination methods – thermal, solvent-based (optionally ultrasound-assisted), mechanical and scCO₂-based – will be investigated. The goal is to recover high-quality active materials, reintegrate them into cell manufacturing and thus close local material loops.
Work Plan
The project consists of five work packages:
WP0 Project management: Project control and partner coordination throughout the entire project: reporting, controlling, milestone monitoring and continuous liaison with the associated partners
WP 1 Recycling infrastructure, laboratory scale: Establishment of the laboratory-scale infrastructure for the direct recycling of electrode scrap and its integration into the existing research environment at PEM. Following the preparation of detailed specifications, the work comprises procurement, installation by qualified personnel, acceptance testing and the integration of existing equipment. Procurement includes a complete laboratory environment with ventilation and exhaust air treatment, equipment for chemical delamination.
WP 2 Recycling infrastructure, pilot scale: Specification, procurement, set-up and commissioning of the scaled process route at Fraunhofer FFB. Three core process form the process chain: Vacuum shredding, Supercritical CO₂ extraction, classifier
WP 3 Analytics and cell testing infrastructure: Installation and commissioning of the complementary laboratory infrastructure for the ongoing testing and validation of material, electrode and cell quality.
WP 4 Process optimisation: Iterative testing and optimisation of the recycling processes. Fraunhofer FFB supplies electrode scrap with known composition and known material ratios
WP5 Scale-up concept development: The most promising routes are scaled up
Exploitation of Results
»NRW-DiRecLab« will deliver the first robust comparison of five direct recycling process routes – thermal, solvent-based (optionally ultrasound-assisted), mechanical and supercritical CO₂ extraction – including quantified findings on recyclate quality (purity, particle morphology, particle size distribution) and on the performance of test cells with varying recyclate contents against a benchmark. Building on this, a concept for scaling the most promising route to gigafactory level will be developed together with the associated partners. The results will be exploited scientifically through publications, conference contributions and a doctoral dissertation, and commercially through transfer into industrial application: the infrastructure serves as a demonstration and development centre for joint research and industry projects, remains available long-term via usage and framework agreements, and can be opened up to further material streams – a tangible contribution to closed local material loops and raw material security in NRW and Europe.
