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DUESENFELD - ECO-FRIENDLY RECYCLING OF LITHIUM-ION BATTERIES
- 1. Licensing of the Ecofriendly Duesenfeld Recycling
- 2. Corporate Presentation • Patent Discharge • Licence description • Advantages • Patent Vacuum Drying • Licence description • Advantages • Patent Hydrometallurgy • Licence description • Advantages Patents
- 3. Process Chain The Duesenfeld recycling process chain involving mechanical processing and hydrometallurgy was consistently developed with the aim of recycling all materials with the highest efficiency in the best possible quality. Discharging Disassembly Duesenfeld mechanical process Duesenfeld hydrometallurgical process Reclaimed residual energy Battery system housing, battery management system, screws, cables, cooling system Electrolyte, copper, aluminium, black mass (graphite, cobalt, nickel, manganese, lithium) CoSO4. NiSO4 MnSO4. Li2CO3 graphite
- 4. Patent Discharging • Discharge independent of SoC-level, voltage, age and manufacturer typ • Automated deep discharge connected in series on only one electronic load • High security through software monitoring Description Electronic Load Duesenfeld Discharging 12 V 34 V 60 V 30 % 65 % 22 V Modul System Cell 60 V Modul 34% System
- 5. Patent Discharging • No high-temperature treatment, no toxic filter material • No water treatment, no wastewater • Disassembly no need high voltage personal • Very high linear discharge capacity leads to high throughput and high efficiency • Battery power is used to operate the plant • Independent of rising energy costs Advantages Up to 50% of Duesenfelds total energy consumption is spent from discharged batteries >1 kWh Typical battery size (no portable batteries)
- 6. Patent Vacuum drying • Shredded material is dried below 80°C in order to avoid the formation of hydrogen fluoride • Vacuum distillation of the solvents of the electrolyte • Duesenfeld Blackmass inert • Product status for Blackmass Description 0 5 10 15 20 20 25 30 35 40 45 50 55 60 65 70 75 80 85 F-Ion-Concentration [mg/l] Temperature of shredded battery fragments [°C] Temperature dependence of HF formation1) DUESENFELD OPERATION TEMPERATURE
- 7. Patent Vacuum drying • CO2 savings = Cost savings • 4.8 t CO2 saving per 1 ton battery compared pyrometallurgical process • 1 ton CO2 savings per 1 ton battery compared to need of gas scrubber • No CO2 emission penalties but credits • Transport cost saving: product and no dangerous goods Savings 0 5 10 15 20 20 25 30 35 40 45 50 55 60 65 70 75 80 85 F-Ion-Concentration [mg/l] Temperature of shredded battery fragments [°C] Temperature dependence of HF formation1) DUESENFELD OPERATION TEMPERATURE
- 8. Patent Vacuum drying • No operating costs for exhaust gas scrubbing, less maintenance time • No investment costs for exhaust gas scrubbing, no expensive corrosion-resistant materials required, reduced equipment dimensioning • No expensive disposal and landfill costs for toxic filter materials or wastewater • Short drying time leads to higher efficiency • Optimal sorting of the black mass Savings 0 5 10 15 20 20 25 30 35 40 45 50 55 60 65 70 75 80 85 F-Ion-Concentration [mg/l] Temperature of shredded battery fragments [°C] Temperature dependence of HF formation1) DUESENFELD OPERATION TEMPERATURE
- 9. • Condensed solvents of the electrolyte are clear • Purity of over 99.5% • Further Destilation for new Batteries Recovered reusable Electrolyte Patent Vacuum drying Advantages
- 10. Duesenfeld Mechanical Recycling efficiency Blackmass 57% Aluminium foil (Kathode) 11% Aluminium Heavy Parts 11% Plastic foil (Seperator) 9% Copper foil (Anode) 5% Plastic Heavy Parts 5% Ferus Heavy Parts 1% Copper Heavy Parts 1% Composition of end products depending on input material Analysis at battery cell and module level Highest recycling efficiency due to low-temperature process, also solvents of the electrolyte, lithium and graphite can be returned to the material cycle Highest purity grades: • Blackmass >98% • Copper >95%
- 11. Patent Vacuum drying • The protected area of the Duesenfeld vacuum drying is below 80 degrees • Reduced legal/governmental approval processes (compared to high-energy thermal processing) • Faster profitability due to lower investment and operating costs Advantages 0 5 10 15 20 20 25 30 35 40 45 50 55 60 65 70 75 80 85 F-Ion-Concentration [mg/l] Temperature of shredded battery fragments [°C] Temperature dependence of HF formation1) DUESENFELD OPERATION TEMPERATURE DUESENFELD PATENTED TEMPERATURE RANGE
- 12. Patent Vacuum drying • Recycling of all Li-Ion cell types • Suitable for low-priced cell chemistries • Duesenfeld Blackmass inert and no self heating • Easy scalable technology • Denser recycling network Advantages NMC Lithium Nickel Manganese Cobalt Oxide NCA Lithium Nickel Cobalt Aluminum Oxide LFP Lithium Iron Phosphate Na Sodium Ion LMO Lithium Manganese Oxide LTO Lithium Titanate
- 13. Patent Vacuum drying Advantages Highest Recyling efficiency: • No weight loss • No processing additives needed • 100 % weight yield due to low- temperature process Alu Housings Electronics Plastics Cables Black Mass Electrolyte Heavy Metal Parts (Alu, Cu, Fe) Metal Foils (Alu, Cu) Plastics Battery systems in tons no weight loss, no additives
- 14. • New cathode and anode material • Removal of all disturbing fluorides by highly concentrated sulphuric acid • The graphite is not damaged and can be reused in new cells • End products: NiSO4, CoSO4, MnSO4, Li2CO3 (battery grade) and graphite. Description Patent Hydrometallurgy C 42% O 21% Li 4% F 2% Al 2% Co 4% Cu 2% Mn 4% Ni 18% P 1% Fe 18.0 Li 2.2 P 14.0 C 40.5 O 21.0 Al 1.2 Cu 1.0 F 2.1 NMC Blackmass Material content in % LFP Blackmass Material content in %
- 15. Duesenfeld exceeds the current requirements of the EU Battery Directive 2006/66/EC many times over. EU Directive CO2-Emission: • a carbon footprint declaration requirement, applying as of 1 July 2024, • a classification in a carbon footprint performance category and related labelling (as of 1 January 2026) • a requirement to comply with maximum lifecycle carbon footprint thresholds (as of 1 July 2027) Recyling rates: • LIB Recyling efficiency by weight: 65% by 2025 70 % by 2030 Material recovery targets: • 90% for cobalt, copper, lead and nickel, and 35 % for lithium by the end of 2025 • 95% for cobalt, copper, lead and nickel, and 70 % for lithium by 2030 No Green Washing • High recovery rates • High-quality secondary raw materials • Duesenfeld also recovers graphite, electrolytes and lithium • Material recycling Duesenfeld Prozess Advantages
- 16. • >10 years of R&D experience • Industrial recycling plant 500 kg/h, 3-shift operation • Duesenfeld licensed worldwide Licensing of the Ecofriendly Duesenfeld Recycling
- 17. DUESENFELD Licensor Know How Support Plant Manufacturer PLANT MANUFACTURER Plant Construction Individual Engineering Support Operator OPERATOR License Customer Customer for plant manufacturer Licensing of the Ecofriendly Duesenfeld Recycling
- 18. Licensing of the Ecofriendly Duesenfeld Recycling Duesenfeld GmbH Rothbergstraße 8 38176 Wendeburg Tel +49 5303 508 28 - 0 Fax +49 5303 508 28 - 200 Mail info@duesenfeld.com
Editor's Notes
- Thank you for the introduction, Mr. … and thank you for the invitation. My name is Till Bussmann, I‘m the CTO at the Duesenfeld Company. Introduction battery recycling, competetiv advantages to the duesenfeld process, focused on patents,
- Inventions about discharge and vacuum drying and hydrometallurgy The Duesenfeld Process is a low temperature process in order to save CO2
- The goal of Duesenfeld since the beginning was always to recover all materials with the highest efficiency in the best possible quality. Also the cheap materials like solvents or graphit back in order to save CO2. Discharging necessary, energy free, voltage free, cable ect. Recoverd, after this shredding, vakuum drying, recover solvent, sorting
- Grid refeeding electronic load, reversed voltage, automated process
- Deaktivation 0 volt, extremly safe, extremly efficient process, Dismantling can be safely automated
- This is the most important invention of the Duesenfeld process, Shredded material is dried without formation of HF.
- CO2 saving is the reason for electromobility Recycling process must be CO2 saving The efficiency and quality of the recycled material is decisive for the CO2 saving, while at the same time considering the total effort required. CO2 release always equates to cost. E.g. heating 1 tonne of battery material costs energy and releases CO2. Duesenfeld saves CO2 and operating costs
- Duesenfeld does not require flue gas scrubbing and thus saves operating costs Low drying time is the core process: no heating times and no cooling times, factor 4 Fewer mixers are needed to ensure the desired throughput (more mixers = higher investment costs) No corrosion-resistant material: higher investment costs factor 2-3 Higher processing costs Seals are attacked more quickly Maintenance times are therefore higher.
- When drying above 80 degrees, the solvents are so contaminated by reaction substances of hydrogen fluoride that reprocessing is not possible. Distillation into DMC, EMC
- By operating in the protected temperature and pressure range, CO2 and costs are saved. Cost savings go hand in hand with CO2 savings. Breakeven is achieved faster
- Low-cost cell chemistries require CO2 sparing and cheap process because revenues are low.
- As you see here, when we put 100 tons inside the process we take 100 tons outside: no weight loss, no additives Nitrogengenerator, activkohle for safty after destillation
- Fluorid removing at the beginning of the process for high quality low-temperature process, grafit Goal: also to recover the “cheap materials” like graphit and the solvents in order to avoid CO2
- no reuse as building material, e.g. for road construction, Happy for any strong regulation
- Duesenfeld recycles batteries on an industrial scale in order to research close to industry. Our licensees are car manufacturers, battery manufacturers, chemical companies, automotive suppliers and recycling companies.
- Thank you for your attention. We look forward to your contact. If you have any questions, you can ask me now.