Finalization Of The 2CYCLE Project

The innovative investment project 2Cycle (Second Life in Lithium-ion Batteries), based on the circular economy, has concluded after a 24‑month execution period. Its main objective was the eco-design, development, and manufacturing of a new product—a prototype of a second-life battery—by recovering, integrating, and reusing lithium-ion cells or modules in any form, including those from battery electric vehicles (BEV) and hybrid vehicles (HV) that have completed their first useful life. Specifically, for those lithium-ion cells that can be recovered and repurposed, this project has extended their life cycle by refurbishing them into modern battery packs as a renewable energy storage solution for stationary use.

In addition to developing the complex technology involved in this project, a series of demonstrative examples have been created that showcase its potential. The 2Cycle project focused on investments in equipment, machinery, industrial tools, the acquisition of industrial-use land, and even new civil works for the project.

This pioneering circular economy project, focused on minimizing the environmental impact of battery pack manufacturing by reusing discarded lithium-ion cells through an eco-design strategy, has successfully concluded. It has achieved significant advances in the valorization and reuse of electromobility battery waste and in reducing CO₂ emissions, marking a milestone in business innovation at Envirobat Spain.

The 2Cycle project involved a total investment of approximately €736,000, co-financed with the support of the Department of Economy, Businesses, and Employment of the Junta de Comunidades de Castilla-La Mancha through its General Directorate of Companies under the “Adelante Inversión” aid program, which promotes investment and improves business productivity in Castilla-La Mancha. This was co-financed at 80% by the European Regional Development Fund (ERDF), with a grant providing aid at roughly 45% of the approved investment.

The development of the 2Cycle project demonstrates once again that perseverance, the desire to add value, a commitment to innovation, and—above all—the willingness to learn from mistakes are key. Thanks to these principles, Envirobat has achieved significant advancements in substantially improving the sustainability of the battery recycling industry. In doing so, 2Cycle lays the groundwork for a more sustainable future, aligned with the principles of the circular economy and the goal of reducing greenhouse gas emissions by up to 55% by 2050, as set out in the European Union’s 2030 Sustainable Development Program.

Among the most outstanding results of the project are the following:

• The development of demonstrator prototypes for new stationary energy storage solutions, applying state-of-the-art waste processing technologies and establishing the foundations for the industrial scaling of second-life battery manufacturing.
• Transformation of 317 tons of lithium-ion batteries at the end of their first useful life into new second-life products.
• An 86.75% reduction in the environmental impact of manufacturing new battery packs compared to a first-life battery with similar electrical characteristics.
• A reduction of 884.97 tons CO₂eq, supporting the transition towards a climate-neutral economy.
• An 88.89% reduction in the environmental impact associated with 251 tons of recovered material intended for reuse and/or recycling, promoting a new concept of the circular economy within the framework of European waste management.

Envirobat Spain’s CEO stated,

“We are pleased with the results achieved in 2Cycle, as initiatives like these are highly relevant in fostering and driving the demand for recycled and second-life products manufactured in our country, thereby moving more decisively towards a circular economy. 2Cycle demonstrates the technical, environmental, and economic viability of modern recycling processes and technologies, which contribute to the circular economy by recovering and reusing resources—thus extending their useful life as much as possible. This project concludes after 2 years of investment and innovation, proving a more environmentally and economically sustainable process in the energy storage remanufacturing industry. This initiative has been the spearhead of a portfolio of R&D&I projects led by Envirobat, contributing to the growing need for the recovery of critical raw materials and valuable metals demanded by the European Commission.”