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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.”

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.

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.

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.

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.