Jan Diekmann

Realization in a Demonstration Plant

This chapter describes the areas and aggregates, as well as the operating cycle of the realized temporary demonstration plant in Braunschweig. This plant was run by employees of TU Braunschweig and Lion Engineering GmbH. As especially safe processing of entire battery systems had to be assured, the developed safety concept is presented. Overall, the demonstration plant processed 1.4 tons of the battery systems of electric vehicles, reaching a material recycling rate of up to 80%.

The LithoRec Process

The LithoRec projects were funded by the German Federal Ministry of the Environment, Nature Conservation Building and Nuclear Safety and VDI/VDE Innovation+Technik GmbH. The projects aimed to develop a new recycling process for lithium-ion batteries from electric and hybrid electric vehicles with a focus on energy efficiency and a high material recycling rate. The developed process route combines mechanical, mild thermal and hydrometallurgical treatment to regain nearly all materials of a battery system.

Potential Dangers During the Handling of Lithium-Ion Batteries

Due to their high voltage, high stored energy, and reactive components, lithium-ion batteries present a specific and significant hazard potential. This especially comes into play during recycling because nearly every safety precaution of a battery system and battery cell needs to be bypassed. Because the project partners of LithoRec II spared a thermal pre-treatment step to deactivate the batteries, the hazard potential and its handling played a major role. This chapter gives an overview of the hazards associated with lithium-ion batteries and describes their role in every process step.

Crushing of Battery Modules and Cells

Crushing is a substantial process step for the following separation, as it transfers the battery cells or modules to a storable and conveyable bulk material. Crushing also leads to the opening of the battery cells and release of valuable materials. Because of the deliberate destruction of the battery cells, this process has a high hazard potential due to the remaining attached energy of the battery cells and the flammable electrolyte components. The project partners evaluated requirements for the design of a crusher and drafted a concept for the realization of a safe and efficient crushing process.