Finalization Of The 2CYCLE Project

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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.”

KoM RECOBATS Project

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On February 20, 2025, at the facilities of the Multisectorial Research Technological Center (CETIM), located at the Alvedro Business Park, Calle H, 20, 15180 Culleredo, A Coruña, the Kick-off Meeting (KoM) was held, marking the official start of the RECOBATS project. The project is carried out by a consortium consisting of 11 entities—7 companies and 4 research organizations. The partners in the RECOBATS project demonstrate a high level of complementarity and interrelation, both in the project’s activities and in its market orientation across the various value chains of battery recycling.

Envirobat Spain is joining the RECOBATS project (Development of a Comprehensive Battery Recycling Strategy), whose overall objective is to develop a comprehensive and versatile strategy for the second life and recycling of lithium-ion batteries for electromobility at the end of their useful life. The project covers the research of technologies at different stages of the process: from logistics and transportation safety, deactivation, automatic disassembly, and cell condition diagnostics, to battery regeneration and direct recycling through selective separation for the recovery of cathode, anode, copper, and aluminum, as well as indirect recycling from black mass for the recovery of strategic materials and graphite at a purity level suitable for a second life.

The total budget for RECOBATS is around €4.5M, with public aid exceeding 60% of the investment, and Envirobat has received a grant of over €450,000 for its participation. RECOBATS is being developed with the support and funding of the Ministry of Science, Innovation and Universities of the Government of Spain, which, thanks to the Recovery, Transformation and Resilience Plan, has deployed new scientific and innovation policy instruments oriented towards priority strategic areas. Among these instruments is the Science and Innovation Missions Program of the Center for Technological Development and Innovation E.P.E. (CDTI) in strategic lines of the State Innovation Agency (AEI), through the “Transmissions Initiative 2024” call. The objective is to promote knowledge transfer and foster collaboration among public institutions or entities (such as Technological Centers and Universities), private industrial companies, and specialized private R&D centers to jointly develop coordinated R&D actions.

The project will have a duration of 48 months, and its initiatives will significantly contribute to the improvement of environmental sustainability, reduction of landfill waste, and the promotion of electromobility and renewable energy. The outcome of RECOBATS will boost the recovery of critical metals and improve environmental sustainability by increasing the recovery of lithium by 76% compared to the current state of the art, 28% for cobalt and nickel, and more than 30% for copper. This will reduce CO₂ emissions by at least 70% compared to the extraction of these critical minerals through traditional mining.

Envirobat Spain’s CEO, Don Borja Álvarez, attended the RECOBATS KoM and stated:

“Envirobat’s expertise in disassembly processes and the previous research developed in this area make it a unique company for achieving the objectives set out in the project. Our research and participation will be aimed at obtaining a comprehensive view of the battery—from the module to its recycling—also considering possible alternative second-life applications once the automotive lifecycle has ended, as well as the recyclability of its components. For Envirobat, it is a challenge to devise a new recycling and recovery process compatible with battery technologies, one that surpasses current recyclability thresholds by adopting a cleaner, more sustainable, and environmentally superior technology that is also more selective and efficient in the extraction and recovery of the metals present in the batteries.

We hope that the experience and development of RECOBATS will generate opportunities for the implementation of new projects based on Innovation and Research, with the commitment and responsibility to enable sustainable growth based on a circular economy. Devising new recycling and recovery processes compatible with discarded battery technologies and fostering Industrial Symbiosis will be Envirobat’s new proposals in the near future, to continue adding value to the recycling industry’s value chain—and above all, to learn.”

Completion of the OSAM Project

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The OSAM project (OPTIMUN SHREDDER ALKALINE MACHINE) was carried out solely by ENVIROBAT ESPAÑA, thanks to the support received from the Ministry for Ecological Transition and the Demographic Challenge (MITECO) of the Government of Spain, under the framework of grants to boost the Circular Economy of the Recovery, Transformation and Resilience Plan (PRTR-EC) funded by the European Union – Next GenerationEU. Specifically, the grant amounted to 55% of the investment executed in the project.

OSAM had an execution duration of approximately 17 months, and its main objective was to improve the mechanical treatment process of alkaline battery waste through the replacement of old equipment with new, modern machines that form a state-of-the-art recycling treatment system. This upgrade significantly enhanced the recycling process of these wastes, achieving an increase in the recovery and utilization of by-products from 15% to 66.17%, which are destined to serve as secondary raw material for various applications within the industrial sector.

The project known as OSAM holds high strategic importance in overcoming the current weakness of the European Union (EU). For this reason, the European Commission approved a regulation on Fundamental Raw Materials last year, under which it is expected that the demand for rare earth elements will increase exponentially in the coming years.

The OSAM project promotes an effort to overcome the EU’s limited production capacity of critical minerals and the weak development of certain segments that are currently affecting the value chain of the continent’s industrial sector.

Among the objectives achieved with the execution of the OSAM project, the following stand out:

  • Reduction of 2,774 tons of alkaline battery waste at the end of its useful life.
  • Recovery of 1,835 tons of high-quality by-products.
  • Reduction of 2,798 tons CO2eq in CO2 emissions.
  • Increase in the recovery and utilization of by-products from alkaline battery waste from 15% to 66.71%, surpassing the current state of the art.
  • Increase in the share of secondary raw materials in the industrial market, with 1,145 tons of Zinc and valuable metals, thereby promoting the culture of Industrial Symbiosis in the mutual utilization of materials and resources, profitably benefiting all stakeholders involved.
  • The measures implemented improved the overall energy efficiency of Envirobat’s industrial facility, providing a reduction of 14.24% in its energy consumption (2.96 MWh/month).
  • The execution of the OSAM project stimulated knowledge and research into new recycling processes, specifically in the recovery of by-products and their utilization as secondary raw material in the industry’s value chain.

The experience and development achieved in this project will create opportunities for the implementation of new projects based on Innovation and Research, with a commitment and responsibility to enable sustainable growth based on a circular economy. Developing new recycling and recovery processes compatible with the technologies of discarded batteries will be Envirobat’s new proposals in the near future, aiming to surpass current recyclability thresholds and add value to the recycling industrial sector.

Finalization of Ausebat

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Envirobat Spain has completed the AUSEBAT (Automatic Selection Battery) project, whose main objective is to develop significant improvements in the management of waste from AA and AAA batteries, specifically in the triage, classification, and selection process of these wastes arriving at its facilities. This was achieved by incorporating a modern and innovative classification and selection process (pioneering and unique in Spain, having previously only been tested in diamond mines) that guarantees an efficiency of 99.9% through the use of multi-density channels. The simultaneous use of multiple density curves allowed for unprecedented separation performance, thanks to the features of the software integrated into the modern equipment, developing the following:

  • The processing of information on objects and areas;
  • Direct detection of objects via software – eliminating the need for 3D laser;
  • Resource optimization; and,
  • Flexibility, due to the use of new X-ray sensor technologies.

The AUSEBAT Project was born from the need to provide innovative solutions in waste management and the environmental challenges it entails. The proper and correct selection, triage, and classification of waste from AA and AAA batteries reduces contamination risks, increases recycling levels, and enhances the recovery of components present in them as secondary raw material.

AUSEBAT had an approximate execution duration of 16 months and was developed solely by Envirobat and its talented team of professionals, who continue to work toward building a better future. The successful implementation of the project has had a significant impact by creating highly qualified, high-value jobs in the recycling industry and providing the company with enhanced competitiveness to ensure stability and competitiveness for its plant. Moreover, it contributes to developing and strengthening a highly skilled workforce across all parts of the recycling industry’s value chain.

The AUSEBAT Project has been promoted by the Ministry of Sustainable Development and its Directorate General for the Circular Economy of the Junta of Communities of Castilla-La Mancha, within the framework of its Aid Program provided under the Support Plan for the Implementation of Waste Regulations of the Recovery, Transformation, and Resilience Plan funded by the European Union – Next Generation EU, specifically with an aid intensity amounting to 70% of the investment made in the project.

With the development of AUSEBAT, the following most significant achievements can be mentioned:

  • Substantially improved the classification, selection, and triage process of discarded AA and AAA batteries, obtaining from them a portfolio of high value-added by-products for their use as secondary raw material.
  • Enhanced the overall energy efficiency of Envirobat’s industrial facility, resulting in a 21.08% reduction in energy consumption.
  • Supported the transition towards a climate-neutral economy with a considerable reduction in GHG (CO2) emissions, specifically: 2,600.09 t CO2eq.
  • Contributed to drastically reducing the environmental impact generated by 2,960.931 tons of AA and AAA battery waste within the framework of European waste management.
  • Reduced the use of primary materials: lowering the gross demand for virgin Zinc raw material by 319.42 tons by substituting it with high-quality Black Mass as secondary raw material.
  • Demonstrated a technically viable, economically sustainable alternative that offers low-impact environmental solutions.
  • Showed a pathway towards an innovative future business model based on Industrial Symbiosis and the Circular Economy.
  • Stimulated knowledge and research into new recycling processes for recovering by-products and utilizing them as secondary raw material in the industry’s value chain.
  • Raised public awareness in the SME and industrial sectors, demonstrating that Industrial Symbiosis is possible and that waste is an untapped resource.
  • Created new jobs – sustainable, stable, and qualified “Green Jobs.”

The knowledge acquired by Envirobat Spain, as a result of the industrial innovation carried out, will undoubtedly help in the implementation of new lines of research, experimental development, and industrial innovation. In this regard, the know-how acquired through the development of the project is fundamental in addressing and focusing on other R&D projects.