Fraunhofer FFB in Münster and the Production Engineering of E-Mobility Components chair at RWTH Aachen University are establishing a new research infrastructure under the NRW-DiRecLab project to advance direct recycling routes for electrode scrap from battery cell production. The initiative is described as unique in Germany and Europe and is intended to support the recovery of high-quality active materials for reuse in cell manufacturing.
Within the project, PEM will host a modular, flexible laboratory-scale environment for recycling research, while Fraunhofer FFB will build a scaled pilot-scale process route. That pilot setup will combine vacuum comminution, supercritical CO2 extraction, and vibrating-screen classification, supplemented by analytics and cell-testing capabilities. Together, the facilities are designed to enable systematic investigation of direct recycling methods and the resulting material quality.
The project will evaluate five process routes that use different delamination approaches: thermal, solvent-based methods with optional ultrasound assistance, mechanical methods, and supercritical CO2-based processing. Researchers aim to compare the routes under controlled conditions and determine which approaches are most suitable for recovering recyclable active materials from battery production scrap.
The work plan is divided into five packages covering project management, laboratory-scale infrastructure, pilot-scale infrastructure, analytics and cell testing, process optimization, and scale-up concept development. Across these phases, the project will focus on procurement, installation, commissioning, iterative testing, and optimization of the recycling processes.
According to the project description, NRW-DiRecLab is expected to provide the first robust comparison of the five direct recycling routes, including measured results on recyclate purity, particle morphology, particle size distribution, and the performance of test cells containing varying amounts of recyclate against a benchmark. The findings will also support development of a scale-up concept for the most promising route toward gigafactory-level deployment.
The project is intended to produce both scientific and industrial outcomes. Scientific dissemination will include publications, conference presentations, and a doctoral dissertation. Commercially, the infrastructure is expected to serve as a long-term demonstration and development center for joint research and industry projects, with potential expansion to additional material streams. The stated goal is to contribute to closed local material loops and improve raw material security in North Rhine-Westphalia and Europe.
Source: Fraunhofer FFB
