FREE4LIB aims to develop and validate innovative technologies (TRL 5–6) to improve the recycling of end-of-life lithium-ion batteries (LIBs). The project targets six sustainable recycling processes, covering dismantling, pre-treatment, and material recovery — while also advancing solutions for material reuse and electrode synthesis within the battery value chain.
Deliverable D3.8 summarizes the laboratory-scale results achieved in Work Package 3 (WP3) and outlines the methodology for scaling up the most promising technologies in the next project phase (WP4).
Context and objective of the deliverable
WP3 focuses on developing technologies for the recovery and revalorization of valuable materials such as metal oxides, metals, and polymers.
The objective of this deliverable was to:
• Consolidate laboratory-scale results,
• Identify the technologies ready for scale-up,
• Define methodologies for industrial implementation,
• Support the validation of at least eight innovative recycling technologies.
The technologies selected for scale-up cover the entire battery recycling chain, from robot-assisted dismantling to material reuse in new battery cells.
Key findings
Laboratory results confirm the strong potential of several technologies:
Robotic dismantling and advanced pre-treatment methods improved safety, precision, and material separation.
• A combined pyro-hydrometallurgical process proved effective for recovering lithium, cobalt, nickel, and manganese from black mass.
• Recycled materials were successfully reused to synthesize new cathode materials (NMC622 and LNMO).
• Plastic recycling routes were validated, enabling reprocessing into reusable thermoplastic compounds.
• Recycled aluminium from battery packs was converted into high-quality powder suitable for additive manufacturing, confirming its viability for high-value applications.
These results demonstrate that multiple recovery and reuse technologies are ready to move toward scale-up.
Recommendations and next steps
Based on these results, FREE4LIB will now focus on:
• Scaling up selected technologies in Work Package 4, targeting TRL 5–6.
• Further optimizing robotic dismantling and electrohydraulic fragmentation systems.
• Industrial validation of metal recovery and cathode synthesis processes.
• Expanding direct recycling and material reuse applications.
• Strengthening cross-sector reuse opportunities for recovered materials.
The laboratory results confirm that FREE4LIB is on track to validate a comprehensive portfolio of recycling and revalorization technologies, supporting the development of a circular and sustainable European battery ecosystem.
You can read the full deliverable here
