University of Münster Develops Innovative Recycling Method for Lithium-Ion Batteries
Scientists at the University of Münster Develop Innovative Recycling Process for Lithium-Ion Battery Production Waste
Researchers at the University of Münster have presented a novel process for recycling production waste generated during so-called dry processing of lithium-ion batteries. The method does not require the use of solvents, preserves the properties of materials, and enables recovered cathode powder to be reused directly in the production of new electrodes.
Goodbye to Energy-Intensive Drying and Toxic Solvents
In traditional battery manufacturing, active materials are mixed into a slurry using toxic solvents such as N-methyl-2-pyrrolidone (NMP). This process requires subsequent energy-intensive drying and solvent recovery, which increases both costs and environmental impact.
An alternative is the dry method, in which polytetrafluoroethylene (PTFE) serves as the binder. This eliminates the need for solvents and drying, lowering production costs. However, this technology generates more waste — particularly in the form of cut-off pieces of the cathode layer. This poses a significant issue, as the cathode is the most expensive component of the entire battery.
Dry-Milling Recycling
A team from the MEET Battery Research Center in Münster has developed a solution that enables efficient recycling of this waste. The new method is based on mechanical processing in dry mills. As PhD researcher Maike Michelle Gnutzmann explains, the process gently separates the cathode composite from the aluminum current collector and grinds it in a way that preserves the structure of the active material.
The result is a powder containing cathode material, PTFE binder, and conductive carbon in their original form. Crucially, this powder requires no additional processing and can be directly reused for electrode production.
Economic and Ecological Advantages
The method completely eliminates the need for high temperatures or toxic chemicals, making it environmentally friendly. A life-cycle analysis conducted by the researchers also confirmed that the process is economically viable and scalable for industrial applications.
The findings were published in the prestigious journal Advanced Energy Materials, under the title “A Dry-Mechanical Approach for Scrap Recycling of Dry-Processed Lithium-Ion Batteries.”