Duesenfeld
Breakthrough in Eco-Friendly Recycling for Lithium-Ion Batteries

The escalating adoption of electric vehicles (EV) as a climate-conscious transportation choice has marked a significant stride towards sustainability. For this movement to reduce carbon footprint, the recycling of lithium-ion batteries—the lifeblood of EVs—must align with eco-friendly principles. Conventional recycling methods fall short, generating excessive carbon emissions along with inefficient metal extraction.

Duesenfeld, a battery recycling technology provider, is at the forefront of innovation in lithium-ion battery recycling technology. It has revolutionized the traditional high-temperature melting recycling process of lithiumion batteries with its innovative low-temperature process, honed through years of dedicated R&D activities.

The groundbreaking process eliminates the requirement for high-temperature process and effectively retrieves graphite, electrolytes, and lithium for material recycling. Its exceptional material recovery capability surpasses current technologies, showcasing a strong commitment to environmental sustainability and operational excellence.

In the Duesenfeld process, no toxic gases such as hydrogen fluoride are produced during the production of the inactive, non-hazardous black mass. This enables the recovery of solvents and lithium to a qualitatively and quantitatively much greater extent than with other processes. The low process temperatures also enable recovery of graphite. The success of the reduction of greenhouse gases through electromobility is significantly related to the recycling of the battery.

“We are driven to relentlessly seek out the most eco-friendly recycling solutions, prioritizing the highest CO₂ savings, while keeping a vigilant eye on the economic viability of the process,” says Andrea Mirandola, sales director at Duesenfeld.

Duesenfeld’s triumph in securing the esteemed German Sustainability Award 2024 marks a significant milestone in its journey toward eco-conscious excellence. The award is in recognition of its R&D activities in developing environmentally friendly recycling processes for lithium-ion batteries. Duesenfeld GmbH has also secured the top spot in the Company sector for Energy Storage and Transmission Technology, solidifying its position as a leader in sustainable practices.

A key metric that distinguishes Duesenfeld is its exceptional recycling rate. Through a combination of mechanical and methodological processes, it achieves 91 percent recycling rate at the cell level, outperforming the 32 percent achieved by traditional methods. It reduces the carbon footprint of the recycling process, resulting in a saving according to LCA screening of 4.8 tons of CO₂ per one ton of recycled batteries compared to standard methods.

Another notable aspect is its hydrometallurgical component, which recovers materials of such high quality that they can be used to produce new batteries. This closed-loop approach underscores Duesenfeld’s steadfast dedication to sustainability and circular economy principles. In line with commitment to sustainability, Duesenfeld’s waste-free process produces no toxic gas byproducts, making it eco-friendly. This is a stark contrast to traditional methods that emit hazardous gases like hydrogen fluoride, requiring gas scrubbers and specialized equipment.

Safety is paramount in battery recycling, and Duesenfeld addresses this by emphasizing fully discharging batteries before recycling. This reduces the risk of accidents related to high-voltage components and potential thermal runaway, ensuring safer working environment. Energy efficiency is another priority for Duesenfeld, with nearly 50 percent of the required energy for its recycling line recovered from the processed batteries.

Rather than operating as a traditional recycling company, Duesenfeld develops cutting-edge technology and licenses it to other companies. It has established a network of plant engineering partners worldwide to deliver solutions to customers. This maximizes the impact of its eco-friendly technology in reducing CO₂ emissions and optimizing cost savings in the recycling process.

The robustness and reliability of Duesenfeld’s recycling system are proven by continuous efficient operations in three shifts, five days a week. Customers licensing its technology receive the same efficiency of a thoroughly tested and optimized recycling line.

Duesenfeld’s advantage lies in its cutting-edge technology and in its practical approach to R&D. Its team of scientists and engineers collaborates closely with OEMs and has access to the latest battery samples, enabling research under realworld conditions and adapt the Duesenfeld process to evolving battery chemistries and technologies in their industrial-scale recycling facility.

The company makes a difference with its dedication to continually develop eco-friendly, cost- and energy-efficient recycling solutions. In an increasingly sustainability-focused world, Duesenfeld’s commitment to CO₂ savings and circular economy principles positions it as a formidable force in the lithium-ion battery recycling industry, paving the way for a greener and more sustainable future.