Institut für Werkzeugmaschinen
und Fertigungstechnik
Recycling of lithium ion batteries from electric vehicles
Stefan Andrew, 22nd and 23rd of September 2015,
20. Umbeto User Workshop, Heidelberg
Institute of Machine Tools and Production Technology
Who are we? And what do we do?
Battery LabFactory Braunschweig
Material Development
2 µm
Recycling
Production of Electrodes
Diagnostics,
Metrology,
Simulation
Vehicle Design
Production of Cells
Life Cycle Analysis
Production of
Modules and Systems
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 2
Institut für Werkzeugmaschinen
und Fertigungstechnik
Who are we? And what do we do?
The Lithorec Projects
Lithorec I & II „Recycling of
Lithium-Ion Batteries“
Fundamental and applied research for
lithium ion batteries in electric vehicles
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 3
Institut für Werkzeugmaschinen
und Fertigungstechnik
Agenda
1 Motivation
2 Lithium ion batteries and their recycling
3 Assessment of the recycling process
4 Conclusions
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 4
Institut für Werkzeugmaschinen
und Fertigungstechnik
Motivation | Motorization and End-of-Life Vehicle (ELV)
end-of-life
vehicles / year
motorization
[cars per
1000 inhabitants]
500
Ђ
400
Germany
300
200
100
India
0
development
growth
maturity and saturation
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 5
time
Institut für Werkzeugmaschinen
und Fertigungstechnik
Motivation | Technology Shift – From Fuel to Electricity?
Ђ
[The e-up! Environmental Commendation – Background Report]
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 6
Institut für Werkzeugmaschinen
und Fertigungstechnik
Motivation | New Hot Spots – Manufacturing
The carbon footprint of the battery‘s production
phase is almost as high as the carbon footprint
of the rest of the vehicle components.
Source: Volkswagen
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 7
Institut für Werkzeugmaschinen
und Fertigungstechnik
Agenda
1 Motivation
2 Lithium ion batteries and their recycling
3 Assessment of the recycling process
4 Conclusions
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 8
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Battery systems in
vehicles
General structure of battery systems
Battery system
Battery pack
Cell
Module Strand
Cell
Insolation
Switch
Housing
Ђ
Heating
Cooling
Battery
management
system
Module
Display
Battery pack
Source: Wallentowitz, 2006; Ketter et. al, 2009
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 9
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Battery cell
Electrolyte
Oxygen
Metall
Lithium ion
Carbon
Separator
Charge
Discharge
Negative Electrode
Separator
Positive Electrode
Source: Tschöke
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 10
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Recycling Processes
battery
management
system
re-use stationary
condition valuation
battery
system
usage
mobile
cell
disassembly of
battery system
recycling
electrode
middling
products
disassembly of cell
aged
electrodes
components
material processing
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 11
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Disassembly
battery
management
system
re-use stationary
condition valuation
battery
system
usage
mobile
cell
disassembly of
battery system
recycling
electrode
middling
products
disassembly of cell
aged
electrodes
components
material processing
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 12
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Disassembly
layout „Scenario 2015“
approx. 2 systems per day
10 different battery designs
1 worker underemployed
cell discharge
storage area
system
discharge
manual disassembly
workplace
layout „Scenario 2030“
system discharge
approx. 450 systems per day
3 different battery designs
10 workers in two shift operation
cell opening
and drying
top cover
removal
manual disassembly
special
workplaces
disassembly
cell removal
storage area
cell opening
and drying
cell discharge
source: Institute of Machine Tools and Production Technology, TU Braunschweig
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 13
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Material Processing
battery
management
system
re-use stationary
condition valuation
battery
system
usage
mobile
cell
disassembly of
battery system
recycling
electrode
middling
products
disassembly of cell
aged
electrodes
components
material processing
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 14
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Material Processing
Shredding of the cells and
sieving/screening of the active
materials
Discharges Cells from
the disassembly
Brine is purified by crystallisation
and ion exchange
salts are splitted using an
electrochemical process
LiOH/Li2CO3
Transition metals solution
Li
solution
Leaching/extraction of the
cathode material
Hydrometallurgic Lithium extraction
Recycling rate up to
85 % of Lithium from LiFePO4
95 % of Lithium from LiNi1/3Mn1/3Co1/3O2
Reagent for new active
material
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 15
Source: IPAT, TU Braunschweig
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Recycling process
without electrolyte extraction
Discharge
Disassembly
Shredding I
Electrolyte condensation
Drying
Є
Metal separation I
Shredding II
Separation electrode
material
Metal separation II
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 16
Institut für Werkzeugmaschinen
und Fertigungstechnik
Lithium ion batteries and their recycling | Recycling process
without electrolyte extraction
Discharge
Disassembly
Shredding I
Electrolyte condensation
Extraction I
Є
Drying
Metal separation I
Shredding II
Separation electrode
material
Metal separation II
Extraction II
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 17
Institut für Werkzeugmaschinen
und Fertigungstechnik
Agenda
1 Motivation
2 Lithium ion batteries and their recycling
3 Assessment of the recycling processЄ
4 Conclusions
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 18
Institut für Werkzeugmaschinen
und Fertigungstechnik
Assessment of the recycling process | Assumptions and
specifications of the Input-Output-Analysis
Assumptions and Specifications:
Functional Unit: „Recycling of 100.000 NMC battery cells“
Location: Braunschweig
Throughput: 250 kg per hour of module material
Usage of additional machines and auxiliary materials
Use of only one step extraction
Є
All calculations in atmospheric pressure
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 19
Institut für Werkzeugmaschinen
und Fertigungstechnik
Assessment of the recycling process | Umberto Modell
Ѕ
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 20
Institut für Werkzeugmaschinen
und Fertigungstechnik
Assessment of the recycling process | Results I
Green House Gas Emissions
300000,00
274513,80
250000,00
kg CO2-eq
Process without
Prozess ohne
extraction
Extraktion
200000,00
150000,00
Process with
extraction
Prozess mit Extraktion
100000,00
75650,29
50000,00
0,00
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 21
Institut für Werkzeugmaschinen
und Fertigungstechnik
Assessment of the recycling process | Results II
Process with
extraction is close to
process without
extraction
Difference 5 %
Green House Gas Emissions
300000,00
274513,80
250000,00
Process without
Prozess ohne
extraction
Extraktion
kg CO2-eq
Improvement:
Reuse of DMC
Output
Reuse of Carbon
active
Reduction of DMC in
the process
200000,00
Process with
Prozess
mit Extraktion
extraction
(after
(2. Optimierung)
ĀЈ
improvement)
150000,00
Process with
extraction
Prozess mit Extraktion
100000,00
75650,29
79726,95
50000,00
0,00
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 22
Institut für Werkzeugmaschinen
und Fertigungstechnik
Assessment of the recycling process | Results III
Integration of the
reference process
Difference 0,6 %
All processes reduce
the emissions
Difficult to choose the
better alternative
Green House Gas Emissions
0
-100000
Process without
-200000
kg CO2-eq
-300000
Prozess ohne
extraction
Extraktion
Є
Process with
Prozess
mit Extraktion
extraction
(after
(2. Optimierung)
improvement)
-400000
-460375
-500000
Process with
extraction
Prozess mit Extraktion
-600000
-700000
-659239
-655162
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 23
Institut für Werkzeugmaschinen
und Fertigungstechnik
Agenda
1 Motivation
2 Lithium ion batteries and their recycling
3 Assessment of the recycling processЄ
4 Conclusions
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 24
Institut für Werkzeugmaschinen
und Fertigungstechnik
Conclusions
Automobiles have developed to one of the most complex consumer products.
Modern cars contain a multitude of different materials that should be recovered.
New processes are under development to cope with the new challenges of
electro-mobility.
Different recycling alternatives have a comparable
environmental impact with very
І
different economic inputs.
There are trade-offs between different impact categories.
Stefan Andrew | Lithim ion batteries from electric vehicles – the recycling and its assessment
2. Oktober 2015 | Folie 25
Institut für Werkzeugmaschinen
und Fertigungstechnik
Institut für Werkzeugmaschinen
und Fertigungstechnik
Є
Lithium ion batteries from electric vehicles –
the recycling and its assessment
Stefan Andrew, 22nd and 23rd of September 2015,
20. Umbeto User Workshop, Heidelberg
Institute of Machine Tools and Production Technology