Fraunhofer Research Institution for Battery Cell Production FFB
Fraunhofer Research Institution for Battery Cell Production FFB

Sustainable Synthesis and Recycling of Phosphorus-containing Materials in Lithium-Ion Batteries

Brief description

The »SuSyPhos« research project aims to further develop the recovery of phosphate from wastewater and manure and its reuse as an electrode material. In collaboration with the MEET Battery Research Center, FH Münster, the Institute for Business Management at Münster University and BeTeBe GmbH, the entire phosphate value-added cycle is being examined.

Currently, the world's phosphate reserves are mainly mined and processed for the production of fertilizers. Over the next few years, the automotive industry plans to increase the use of lithium iron phosphate (LFP) in electric vehicles. An expanded industrial use of phosphate is in conflict here with the agricultural use so necessary for food and animal feed production. The recovery of phosphate will address this conflict, reduce dependence on imports and reduce environmental pollution.

BeTeBe GmbH and FH Münster select the starting materials and separate the phosphate, which is then processed by the MEET Battery Research Centre and synthesized into active material for batteries. Extensive analysis follows the synthesis in order to characterize material properties such as composition, purity, particle size, crystal structure and carbon coating. The electrochemical properties of the synthesized lithium iron phosphate are evaluated through tests in battery cells and modified if necessary.

A life cycle assessment (LCA) and economic feasibility study complete the project. Upstream and downstream steps are also examined in order to analyze the ecological and economic viability of a circular business model. The evaluation takes place under a continuous consideration of the overall system, taking into account possible alternative processing routes. In addition, a consequential LCA enables the effects to be considered at a macroeconomic level, thus answering the question of the ecological added value of comprehensive sewage sludge treatment.

Project schedule

The work plan is divided into five work packages:

1.    Phosphate recovery from wastewater and manure

2.    Purification of the intermediate products

3.    Production of LFP

4.    Characterization and associated analysis

4.1  Analysis of the starting, intermediate and final materials

4.2  Electrochemical characterization of the LFP

5.    Life cycle assessment and economic feasibility analysis

5.1  Life cycle assessment

5.2  Economic feasibility study & patent analysis

Utilization of results

The "SuSyPhos" project is examining the potential of secondary material sources for reintegration into battery cell production as well as their economic and ecological benefits. The innovative substance of the project lies on the one hand in the further development of phosphate recovery from wastewater and manure, and on the other hand in the further development of LFP production. The particular added value lies in the combination and iterative adaptation of the process chain of these two topics. This results in synergy effects that can be used in an integrated process concept for both NRW and national waste management.

Like many other raw materials, phosphorus is now listed by the EU as a critical raw material due to its high dependence on foreign imports. The insights gained will show how waste stream cycles can be closed and counteract dependencies. The growing demand for raw materials due to the massive expansion of battery production capacities is opening up new markets for the processing and reintegration of secondary raw material sources. The requirements of these markets for secondary raw materials and the necessary infrastructure are being investigated in the project. This supports the EU Commission's strategy for securing critical raw materials and offers a specific approach to increasing the security of raw material supply in NRW.