A Fraunhofer IFAM research team has developed a new electrochemical process that could significantly improve the recovery of lithium, cobalt and nickel from used batteries, offering a potential boost to Europe’s supply security for critical raw materials.
Scientists at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM) in Bremen, Germany, are working on the technology as part of the MeGaBat project. Demand for lithium‑ion batteries continues to rise sharply, driven by electric vehicles and consumer electronics. Deloitte figures show lithium imports to Germany soared from 514 million euros in 2013 to 21 billion euros in 2023.
“We want to recover valuable raw materials and rare earths at high yield and high purity, thereby closing the product loop and reducing dependencies,” says Julian Schwenzel, Head of Electrical Energy Storage at Fraunhofer IFAM.
The new method channels wastewater from battery recycling into an electrochemical reactor fitted with screen‑printed electrodes. According to project lead Cleis Santos, “With their special properties, the electrodes selectively extract and store ions from the wastewater.” The recovered metals are then produced as high‑purity powders.
Unlike conventional pyro‑ or hydrometallurgical recycling, the process requires no acids or bases and uses far less energy. Researchers estimate efficiency gains of 30 to 40 percent, a key advantage as EU rules tighten around carbon footprints and recycled content.
A pilot plant is now under development. The team believes the same technology could eventually be used to recover rare earth elements from electronic waste, as well as support seawater desalination and hospital wastewater treatment.
Image: Critical raw material recovery from battery recycling. Credit: Fraunhofer IFAM.
