Rhinoceros-Faraday-SciencePoster

Batteries are most advanced and key components of energy transition. Despite the technologic advances, they still
have a drawback due to lack of well developed manufacturing technologies and more importantly absence of proper
End of Life ( EoL ) procedure for these expensive, labor and carbon intensive
Currently,
EoL handling trend is sending scrap batteries to recycling facilities. In that way, Raw material supply chain is
supported by recycled materials. Unfortunately, recycling will not be enough by alone to handle scrap batteries post
2030 era due to substantial number of scraps. That’s why, OEMs currently work on recycling alternative solutions such
as refurbishment, reusing, and repurposing.
In this project, holistic battery
EoL approach of batteries, which is scrapped from production and customer was
created. This approach covers development of EoL testing for decision mechanism, reusing application, charging
infrastructure improvement and decentralization of grid via reusing, lastly prevention of possible critical raw materials
(CRM) bottleneck via high efficiency recycling.
Cycle starts with scrap batteries
EoL testing. Scraps are evaluated with EoL test procedure taking into consideration
voltage level, capacity, State of Health , and max current etc. After evaluation, it is decided that whether they are
suitable for second life application or not. If not, scraps are directly sent to recycling process. After determination of
the batteries are suitable for secondary use, selected batteries are dismantled to module level and reassembled with
intended configuration. Total of 20 modules with 142.2 kWh was decided to be used with %80 depth of discharge for
precaution, that correspond to 113.8 kWh energy. The prototype installed as 22 kW AC EV charger supply. It provides
a peak time boosts and grid flexibility. Thus , mutualist ecosystem is created between scrap batteries and charging
infrastructure to accelerate EV transition.
Batteries that failed at tests were directly sent to recycling. In recycling part, local market was prioritized due to
strengthen CRM independency. Consequently, %85 general average recycling efficiency was achieved (Depends on
material %99 Co, Ni, Mn and %85 Li). Besides that, a breakthrough achieved by recycling anode (%33 eff.) and
electrolyte.
Meanwhile, Ford Otosan is actively involved in t
hree Horizon Europe projects: BATRAW [ RHINOCEROS [ and
RECIRCULATE [ that aim to develop innovative routes towards re using and sustainable recycling of LIBs. By
developing novel hydrometallurgical processes, battery passport systems, safe and autonomous dismantling, and
manufacturing high performance electrode from 100% recycled materials,