A next-generation automated, connected, and standardised process for increased safety, efficiency, and sustainability of Li-ion BATTEry REVERSE logistics

BatteReverse aims to enable the next generation of battery reverse logistics (RL). It will develop a more efficient and universal method for battery discharge and first diagnosis for a wide range of Li-ion battery types, safety packaging with a monitoring system reducing thermal runaway risk during transportation of batteries, automated dismantling and sorting of battery components based on a safe and more efficient human-robot collaboration, and a more precise and faster Remaining Useful Life assessment of battery modules for 2nd life applications based on acoustic testing and machine learning algorithms. On top of that, BatteReverse will develop a Battery Data Space with standardised labelling and battery passport functionalities to improve battery identification. We will connect the stakeholders through a community platform and analyse the entire RL process by a digital twin (DT) simulation that will optimise profitability of RL circular business models. The innovations will be integrated and demonstrated in an operational environment in two use-cases for end-of-first-life (EoFL) EV batteries - recycling and repurposing – mirrored with the DT simulation. By 2026 we expect these developments to contribute to following outcomes: increase recycling efficiency by 5%, raise share of repurposed EoFL batteries to 10%, reduce risk of severe events in reverse logistics to 1/10.000, successfully simulate two successful RL business models and to have a stakeholder’s community platform with 50+ stakeholders. These outcomes will contribute to the sovereignty of the EU in the battery sector. By further uptake of the developed results beyond the project, BatteReverse targets to avoid the use of 3.691 tonnes/year of primary critical raw materials, on top of that avoid the deployment of 100,8 MWh capacity of new batteries yearly while capturing an extra €30,24 million/year value out of EoFL batteries and avoiding 31 severe risk events/year within the EU RL battery chain by 2029.