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.”

KoM RECOBATS Project

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

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

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.

LIFE RELIGHT PROJECT

Envirobat España, S.L., part of the ReLiGHT project formed by a consortium of six Spanish companies, which will carry out the tasks and objectives planned within it over seven years, is funded by the European Union’s LIFE Programme, which supports projects for environmental conservation, circular economy, climate action, and energy transition in Europe. The project has an estimated cost of €7.8 million, with public funding of 60%, of which Envirobat has been granted aid exceeding €1 million.

The main objective of the project is to increase resource efficiency by demonstrating the high capacity of a storage solution using batteries from electric cars after the end of their first life, whose current destination would be disposal as waste.

ReLiGHT gives a second life to used lithium-ion batteries from electric vehicles by reusing them as part of an energy storage solution integrated into wind and solar farms. This reuse will lead to the development of a new type of hybrid renewable plant, which will provide a source of energy during periods when renewable sources are not guaranteed, thereby avoiding carbon-based energy sources.

At the end of this extended useful life of the batteries, the project will close the cycle through a recycling strategy led by Envirobat. Furthermore, the project is developing a second-life energy storage system of 5.6 MW/11.2 MWh, which will be validated in a renewable plant led by Capital Energy, the coordinator of the consortium. This plant comprises a 52.2 MW wind farm and a 76.5 MWp photovoltaic plant. The actions will be implemented throughout the entire battery value chain, including their reception, testing, and classification, the assembly of new battery packs, their integration into the renewable energy plant, the replacement of batteries at the end of their useful life, and final recycling.

ReLiGHT has a planned execution period of seven years and aims to achieve results such as the reduction of up to 102.31 tons of used batteries through their transformation into new second-life products for stationary energy storage, thus extending their 1 useful life by 10 years. It also aims to reduce primary energy consumption by 4 GWh/year and CO2eq emissions by 600 tons/year, thanks to the efficient operation and management of the renewable plant and the project’s battery energy storage system.

The OSAM Project

The OSAM Project (Optimum Shredder Alkaline Machine) is a beneficiary of the grant call for promoting the circular economy in companies for the year 2022 by the Ministry for Ecological Transition and Demographic Challenge (MITECO) under the framework of the Recovery, Transformation, and Resilience Plan (PRTR) funded by the European Union – NextGenerationEU.

At Envirobat Spain, we are committed to a circular economy model that focuses on modernizing the Spanish economy, recovering economic growth, and building a solid, inclusive, and resilient reconstruction. Therefore, we are developing the OSAM Project (Optimum Shredder Alkaline Machine), which aims to improve the management of alkaline battery waste and the mechanical treatment process, obtaining high-quality by-products. These by-products will be used as secondary raw materials for recycling valorization processes in a circular economy and industrial symbiosis. The project has a duration of 15.5 months.

Envirobat emphasizes the need to contribute to transforming our production model through innovation and sustainability, aligning with the European Union’s circular economy action objectives. We will make the planned investment in improving the management of alkaline battery waste by implementing separate collections for preparation, reuse, and recycling of other waste. This will generate economic, environmental, and social value, contributing to a new scenario characterized by the consolidation of an innovative, sustainable, and competitive industrial fabric capable of growing within a circular economy framework. We aim to improve the current management of treatment and recycling processes for these waste materials, adopting an environmentally friendly approach that enhances process efficiency and optimization, increases collection volume, and improves treatment. We will obtain high-quality by-products that can serve as resources and secondary raw materials for other small and medium-sized enterprises in the industry.

The OSAM Project stems from the need to offer innovative solutions to minimize the negative effects of generating this waste, reducing the overall impact of its use. We aim to improve the efficiency of its use and promote a low-carbon circular economy model, following the principles of eco-industrialism and fostering industrial symbiosis for efficient functioning of the domestic market and long-term competitiveness of Spain.

Envirobat Spain celebrates that the OSAM Project has been approved in the Final Resolution of the Circular Economy Promotion Grants dated 15-12-2023, under the third category of grants for improving waste management, published by the Ministry for Ecological Transition and Demographic Challenge, General Directorate of Quality and Environmental Assessment. The granted aid represents a total intensity of 55% of the proposed project investment, stimulating the promotion of a national strategy for industrial ecology. This concept is based on the rational management of raw materials and waste in neighboring industries within the same territory, creating a true industrial ecosystem in the region, where each industry benefits from the waste of others.

Envirobat’s goal is to achieve greater sustainability and promote an environment-friendly economy, moving towards a more circular economy that generates benefits such as reducing pressure on the environment, stimulating competitiveness, innovation, and economic growth.

PRESS RELEASE / AUSEBAT PROJECT / ENVIROBAT’S WEBSITE AND SOCIAL MEDIA

At Envirobat Spain, we are committed to #SDG8 Decent Work and Economic Growth, #SDG9 Industry, Innovation and Infrastructure, and #SDG11 Sustainable Cities and Communities. That is why we have developed the AUSEBAT Project (Automatic Selection Battery), which aims to improve the selection and sorting process of battery waste in terms of the purity of the final classified product, achieving a process efficiency of 99.9%. It features multi-density channels: The use of multiple density curves simultaneously will allow for unprecedented separation performance, offering greater resource optimization and flexibility through the use of new X-ray sensor technologies. We incorporate state-of-the-art equipment equipped with highly sensitive (HS) sensors, combined with innovative classification software, to separate these waste materials by atomic density.

The AUSEBAT Project stems from the need to offer innovative solutions in waste management and address environmental challenges. Proper selection, sorting, and classification of these waste materials reduce pollution risks, increase recyclability levels, and improve the recovery of components as secondary raw materials. At Envirobat, we tackle current challenges with sustainable and innovative entrepreneurship actions, transitioning towards a circular model that generates economic, environmental, and social value for the Province of Guadalajara. We aim for a more responsible and competitive model with reduced dependence on natural resources, adopting a systematic and comprehensive approach throughout the value chain.

Envirobat celebrates that AUSEBAT has been one of the eight approved projects in the Provisional Resolution of Grants dated 09-11-2023 under the Fourth Line of Subsidies, which focuses on investments related to collection, sorting, classification, and improvement of existing mechanical-biological treatment plants. This resolution was published by the Directorate General of Circular Economy of the Regional Government of Castilla La Mancha on 10-11-2023. The granted subsidy, representing a total intensity of 70% of the proposed project investment, will stimulate the adoption of new technologies in recycling processes, facilitate increased recovery of by-products as secondary raw materials, and provide an excellent framework to transform the technical and scientific knowledge generated into circular economy-based products.

Envirobat, with its constant capacity to generate innovation through clear methodologies, concrete and sustainable strategies, and the ability to understand current needs in waste management, sees these opportunities as a chance to learn, educate, comprehend, incorporate, and, most importantly, challenge current waste management models. For Envirobat, success is not only about achieving the final goal but also about traversing each stage of the innovation process.

PRESS RELEASE: ENV’S ATTENDANCE AND PARTICIPATION IN THE BATMASS PROJECT KoM

Envirobat España participated with the presence of our CEO, Mr. Borja Álvarez, and the Commercial Director, Mr. Christophe Kleindienst, on October 19th at the Kick-off Meeting of the BATMASS Project, held at the Sala Consiglio, Department of Mechanical Engineering, Politecnico di Milano, Italy.

Envirobat is part of a consortium consisting of 15 entities that will develop the BATMASS Project, including notable participants such as Green Vision SASU, Universita Degli Studi di Pavia (UNIPV), Verkor, Lomarttov SL, Orano Mining, Politecnico di Milano (POLIMI), ERP Italia Servizi SRL, Fundación Corporación Tecnológica de Andalucía (FCTA), Nanofaber SRL, Associazione Fabbrica Intelligente Lombardia (AFIL), N-Able, among others.

BATMASS aims to establish the first Circular Battery Valley in the EU for second-life, recycling, and remanufacturing of materials and black mass. It offers a portfolio of interregional investment in TRL6+ innovations in circular technologies and processes for battery materials. BATMASS mobilizes an interregional ecosystem centered around four demonstrators or “demonstration beacons” aimed at scaling up, commercializing, and deploying innovative green technologies. With a total investment cost close to €10,000,000.00, funded through the EU’s I3 Interregional Innovation and Research program, Envirobat is the 4th partner to receive the highest amount of granted aid for project development, with over €820,000.00.

BATMASS will save 59,000 tons of precursor materials and contribute to achieving the EU’s strategic objectives in terms of resilience and the environment. BATMASS mobilizes an interregional integrated ecosystem focused on scaling up, commercializing, and deploying innovative green recycling technology. Stay tuned for more updates on the EU BATMASS project!

PRESS RELEASE / ATTENDANCE AT THE II MEETING OF THE CIRCULAR ECONOMY AGENTS NETWORK OF CASTILLA LA MANCHA

On October 19th, Envirobat España participated in the sessions of the II Meeting of the Circular Economy Agents Network of Castilla-La Mancha, held at the Cigarral del Ángel Custodio #Toledo Auditorium, organized by the General Directorate of Circular Economy of Castilla-La Mancha. Our R&D Department Director, Mr. Micheel Acosta, participated and was part of the panel on “Advancements and Needs: Preparing for New Initiatives: Secondary Raw Materials in the EU,” sharing the panel with Ms. Margarita Ruiz, Deputy Director General of Circular Economy at the Ministry for Ecological Transition and Demographic Challenge; Mr. Luis Moreno, CEO of the Ecolec Foundation; Mr. Victor Monsalvo, Director of Innovation at Aqualia; and with moderation by the Co-director of the Circular Economy Chair at the University of Castilla-La Mancha.

Envirobat understands that Circular Economy is a sustainable production and consumption model that aims to transition from the loss of value in a linear model to capturing value in a circular model, keeping resources in the chain of productive cycles for as long as possible. Mr. Micheel Acosta presented the 2Cycle Project (Second Life in Lithium-Ion Batteries) developed by Envirobat as a clear example of a circular economy business model in the extension of the lifespan of cylindrical 18650 and 21700 Lithium-Ion battery cells derived from battery waste. The 2Cycle initiative will apply sustainable design implementation (Ecodesign), combining design thinking with circularity methodology, for the manufacturing of new battery packs intended for stationary use in homes, connected to clean energy generation plants, to supply renewable energy to individual mobility vehicles (electric scooters, bicycles, hoverboards, etc.).

The 2Cycle Project aims to reduce 500 tons of this waste, as well as reduce GHG emissions by 1,631.43 t CO2e, promoting a circular business model, enhancing the generation of renewable energy and sustainable mobility, offering scalable and efficient reuse of recovered cells for their second life. This initiative is supported by a grant from the Junta de Comunidades de Castilla-La Mancha “Ayudas – Adelante Inversión” for the promotion of investment and improvement of business productivity, co-financed by the European Regional Development Fund.

2Cycle Project

Envirobat Spain, S.L., is developing the 2Cycle Project (Second Life for Lithium Ion Batteries); its main objective is the Eco-design, development, and manufacturing of a new product, a second-life battery prototype, by recovering, integrating, and reusing cylindrical Lithium Ion cells that have completed their first useful life cycle.

Envirobat Spain, S.L., leading the 2Cycle project, is developing an initiative that aims to promote a detailed, consistent, and value-enhancing Eco-design, so that the second life of batteries achieves optimal performance and refurbishment extends their useful life as long as possible, applying knowledge and technologies, supporting the development of the circular economy, electric mobility, and its value chain.

2Cycle is aligned with several Sustainable Development Goals and promotes the substitution, recovery, and valorization of resources for the ecological transition. This Project/Action is incentivized with a grant from the Investment Support Program: Adelante – Investment in Castilla La Mancha, co-financed by 80% from the European Regional Development Fund.