The rapid growth of lithium-ion batteries (LIBs) in electric vehicles, portable electronics, and renewable energy storage has intensified concerns about raw material scarcity and end-of-life management. Critical elements such as lithium, cobalt, nickel, and graphite require energy-intensive extraction and are often subject to geopolitical constraints.
Addressing these challenges requires efficient recycling strategies and the exploration of second-life applications. Within this context, the FREE4LIB project evaluates the electrochemical performance of new, spent, and recycled battery cells to support a more circular and sustainable battery value chain.
Context and objective of the deliverable
This deliverable focuses on three main objectives:
- Assessing the state of health (SOH) and reuse potential of end-of-life (EOL) battery cells.
- Evaluating the performance of cells incorporating recycled electrode materials.
- Scaling up cell configurations to pouch cell formats, bridging laboratory research and industrial feasibility.
By combining electrochemical testing with material validation, the project aims to determine which batteries are suitable for second-life applications and to confirm whether recycled materials can be reintegrated into new cell production without compromising performance.
Key findings
The electrochemical testing campaign delivered important insights:
- EOL cell screening revealed high variability in remaining capacity and degradation patterns.
- Some cells retained over 50% of their initial capacity and may be suitable for second-life use.
- Others showed severe degradation, swelling, or over-discharge, making them unsuitable for reuse.
- Results confirmed the need for thorough screening and classification before second-life deployment.
- Cells incorporating recycled cathode materials demonstrated promising performance:
- Stable discharge capacities were achieved after initial cycling.
- Slightly higher internal resistance was observed compared to commercial references, indicating room for optimization.
- Results confirm the feasibility of integrating recycled materials, though further improvements are needed for long-term stability.
- Pouch cell scale-up was successfully achieved:
- 300 mAh pouch cells showed stable cycling behavior after initial activation.
- Larger 7 Ah pouch cells were fabricated as benchmarks for future testing.
- These developments mark an important step toward industrial validation.
Recommendations and next steps
Based on the findings, the following actions are recommended:
- Strengthen screening methodologies to safely identify cells suitable for second-life applications.
- Further optimize electrode formulation and processing when using recycled materials to improve cycling stability.
- Continue testing large-format pouch cells to validate industrial feasibility.
- Support WP4 activities by integrating these results into battery pack design and re-manufacturing strategies.
By combining second-life evaluation with recycled material validation, FREE4LIB advances practical solutions for a morecircular, resource-efficient, and sustainable lithium-ion battery industry.
You can read the full deliverable here
