Research and development of a highly automated and safe streamlined process for increased Lithium-ion battery repurposing and recycling

日益增长的电动汽车将引发电池浪费问题（到2040年将达到900万吨/年），尽管许多使用过的锂电池适用于第二生命的额外10年应用，这意味着欧洲有机会减少对能源和原材料的依赖。技术障碍阻碍了锂离子电池的再利用和再循环。除了电池库存的异质性外，评估其进一步使用的条件是一个缓慢的过程，而设备不适合工业环境。此外，拆卸包装和模块是一个昂贵且缓慢的手动过程，因为其自动化面临极其复杂，多规模，杂乱和密集的环境。REBELION将验证两种循环方案（包括轻型电动汽车），以最大限度地提高二次使用寿命和国内应用，通过基于电子噪声分析的破坏性快速电池测试，以及具有针对当前电池类型和格式重新配置能力的自动电池组和模块拆卸系统。此外，一个新的标签系统支持区块链、数字电池护照和生态标签技术，将为拆解商、回收商、再制造商和用户提供关键信息。处理大量废旧电池增加了热跑道事故的风险，因此需要新的安全协议和系统。REBELION将增加热监控，并设计一个智能容器，用于存储和运输，具有热和气体传感层，以监测极限氧气指数和较低的爆炸极限，以及一个冷却系统，当超过阈值时激活。REBELION联盟涵盖所有价值链，包括先进的机器人生产线和汽车制造商，带来关键知识，专有技术和试点验证设施。4个研究中心和7个工业合作伙伴的结合将确保技术从实验室转移到工业环境。

The increasing e-mobility will trigger a battery waste problem (9Mtons/year by 2040) despite that many of the used LIBs are suited for 2nd-life applicationsfor an additional 10 years, representing an opportunity to diminish energy and raw materials dependenciesin Europe. Technical hurdles are preventing the re-use and recycling of Li-ion batteries. Besides the heterogeneity of the battery stock, assessing their condition for further usage is a slow process performed with equipment not suited for industrial contexts while. Dismantling packs and modules is in addition a costly and slow manual process because its automation faces extremely complex, multi-scale, cluttered and densely packed environments. REBELION will validate two circular schemes (including Light e-vehicles) to maximise 2nd life utility and domestic applications, enabled by a disruptive fast battery testing based on Electronic Noise Analysis, and an autonomous pack and module disassembly system with re-configuring capabilities for the ongoing battery types and formats. Additionally, a novel labelling system supported with blockchain, digital battery passport and ecolabel technology will provide key information to dismantlers, recyclers, re-manufacturers and users. Processing large volumes of used batteries increases the risks of thermal runway incidents, requiring thus novel safety protocols and systems. REBELION will add thermal monitoring and the design of a smart container for storage and transportation with thermal and gas sensing layers to monitor the limiting oxygen index and lower explosive limits, and a cooling system that activates when thresholds are surpassed. REBELION consortium covers all the value chain, including advanced robotic line and car manufacturer, bringing key knowledge, proprietary technology, and pilot validation facilities. The combination of 4 research centres and 7 industrial partners will ensure technology transference from lab to industrial context.