Fraunhofer Research Institution for Battery Cell Production FFB RECLAIM
RECLAIM - Recycling Electrode Coatings through Delamination and Re-Integration into Manufacturing
The RECLAIM (Recycling Electrode Coatings through Delamination and Re-Integration into Manufacturing) project develops and industrializes innovative processes for the direct recycling of production waste from battery cell manufacturing. The focus is on delamination the separation of active material and current collector foil using thermal, mechanical, and wet chemical processes. The consortium consisting of Fraunhofer FFB (coordination), RWTH Aachen University (PEM), University of Münster (MEET), and industry partners Otto Junker Solutions (associated partner), NoCanary, and cylib is testing these recycling processes on a technical and pilot line scale for various active materials (LFP, NMC, graphite) and binding systems. The recovered materials are characterized, post-treated if necessary, and directly reintegrated into battery cell production. Compared to conventional recycling processes, this approach can save up to 60% of costs and up to 80% of CO₂ emissions. The project contributes to closing local material cycles, reduces dependence on imported raw materials, and supports compliance with the EU Battery Regulation.
Work Schedule
The RECLAIM project is divided into five work packages, which are distributed among the consortium partners:
WP 0: WP 0 covers project management, which accompanies the project throughout its entire duration.
WP 1: Work package 1 examines the various delamination processes.
WP 2: The recycled material is then characterized and, if necessary, post-treated.
WP 3: Work package 3 reintegrates the recyclate into the production process.
WP 4: Work package 4 carries out a techno-economic and ecological evaluation of the various processes.
Utilization of Results
he results of the project include validated thermal, mechanical, and wet chemical delamination processes on a pilot plant to pilot line scale for various active materials and binding systems. These are supplemented by optimized process parameters for recovering active materials from production rejects and by characterization data on the quality of the recycled materials. The industrial relevance is demonstrated by the production of at least 100 test cells with varying recycled content and the verification of the electrochemical performance of directly recycled materials. A techno-economic-ecological evaluation of the recycling processes investigated provides concrete recommendations for their industrial implementation.
The scientific exploitation takes place through the publication of technical articles, the preparation of a dissertation, and presentations at specialist conferences. In addition, the results will be shared through publications in national and international journals, contributions to conferences, integration into university teaching, and specialist presentations at industry trade fairs. Further knowledge transfer will take place through the transfer of researchers to industry.
Economic exploitation is aimed at plant manufacturers and recycling companies. For plant manufacturers, the developed processes are integrated into the product portfolio and existing plants are further developed to improve functionality and efficiency and strengthen their competitive position. For recycling companies, direct recycling is integrated into the service portfolio and applied in their own pilot and industrial plants with the aim of achieving long-term cost savings, efficiency gains, and higher resource yield with reduced material consumption.
