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LEOREC

Low Energy Oriented LFP Batteries Recycling
Funder: French National Research Agency (ANR)Project code: ANR-23-CE05-0019
Funder Contribution: 670,327 EUR
Description

Concerns over environmental protection and energy independence in Europe are driving a transition towards low-carbon mobility. In this regard, the EU has recently proposed the end of combustion engine vehicles by 2035. This ambitious change can only be achieved if a favorable industrial environment for mass production of electric vehicles (EVs) is established in Europe. To date, the most mature technology is lithium-ion (Li-ion) batteries based on NMC, which dominate the EU market. However, these batteries require the use of cobalt, nickel, and lithium, critical metals produced outside the EU. Fortunately, the substitution of cobalt and nickel is entirely possible thanks to LFP technology, which offers excellent performance in terms of stability, safety, and longevity. This technology has been adopted by China (which produces over 70% of LiBs). However, the shift towards LFP technology seems to be happening with the surge in metal prices, driven by manufacturers such as Tesla and VW. However, this change in strategy to favor LFP batteries will not be sufficient to guarantee the EU's energy independence unless it is accompanied by two key measures: battery production and recycling within the EU. Although many European players have announced the construction of over forty gigafactories to produce batteries for EVs, few are investing in projects to recycle these batteries at the end of their life. Aware of this weakness, the EU is encouraging the development of a strong critical metals recycling industry through stricter regulations and targeted subsidies. In this context, the LEOREC project aims to demonstrate the feasibility of recycling LFP cathodes using mild, green, and low-energy chemistry for their reuse in the local production of new Li-ion batteries. It should be noted that current recycling techniques have been designed to recover high-value economic metals such as cobalt, via conventional methods such as pyro- and hydrometallurgy. However, these are considered non-profitable in the case of LFP. Thus, low-temperature and pressure regeneration methods will be developed in LEOREC to promote the repair of LFP instead of its destruction by conventional methods. This would enable the efficient, sustainable, and economical recycling of LFP cathodes within a circular economy. LEOREC aims to globally evaluate two direct regeneration processes: direct lithiation under ambient conditions (ADL) and direct lithiation under solvothermal conditions (SDL). The more effective of these two approaches, first optimized at the laboratory scale, will then be scaled up by the industrial partner. The main obstacles to overcome are energy, environmental, and societal. Indeed, it is a matter of proposing a method that is (i) energy-efficient (at low temperatures or even at room temperature), (ii) using solvents and lithium sources that are as ecological as possible, while (iii) minimizing the steps required for LFP electrode regeneration. In order to achieve a realistic evaluation of the entire process, electrochemical tests on industrial 18650-type batteries will be performed. The data obtained will objectively compare direct regeneration with conventional methods. If the balance is favorable, this method could be a future technology in the valorization of end-of-life LFP batteries. The success of the LEOREC project relies on the complementarity of industrial and university partners and their experience in the fields of Li-ion batteries and recycling.

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