RE-X

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Battery Production & Inline Process Control - Folge 11

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Navigating the Gigafactory journey with real-time data

Navigating the Gigafactory journey with real-time data

Navigating the Gigafactory journey with real-time data

Navigating the Gigafactory journey with real-time data

Latest Publications and Guides

Content Type: Battery Atlas
Authors: Merlin Frank, Heiner Heimes
Publisher: Battery-News.com

“Battery-News.de” presents a current excerpt of European companies directly involved in or supporting second-life applications of batteries. The map is divided into five categories: Collection and transport to the facility, identification and condition assessment, end-of-life strategy selection, technical refurbishment and integration and installation. Learn more…

Content Type: Training
Author: Systemiq, PEM Motion
Publisher: ITAS

The automotive sector is undergoing a transformation, and the circular economy is becoming a crucial factor for its long-term success. This tailored courses provide you with a unique opportunity to understand and shape this transformation from two crucial perspectives:
Course 1: Circular Cars – Made in Saxony: Strategic Implementation for Business Leadership
In this course, entrepreneurs and business leaders gain valuable insights into the strategic implementation of circular economy principles into their corporate strategy. Learn how transitioning to a circular approach not only promotes environmental sustainability but also enhances competitiveness. From waste reduction to the development of innovative business models, this course guides you towards the sustainable transformation of your organization.
Course 2: Circular Cars – Sustainable Practices in the Workplace: Implementation for Skilled Workers
This course is designed for skilled workers in the automotive industry, offering practical insights into the application of circular economy principles in the workplace. Learn how to use resources more efficiently, minimize waste, and improve the quality of your work. By engaging in these practices, you not only contribute to environmental protection but also enhance your professional qualifications and contribute to your company’s competitiveness. Learn more…

Content Type: Report
Authors: Dr. Susanne Kadner, Dr. Jörn Kobus, Prof. Dr. Martin R. Stuchtey, Prof. Dr.-Ing. Thomas Weber
Publisher: Circular Economy Initiative Deutschland

We are living through times of great change: innovative technologies are being developed at breakneck speed, patterns of consumer behaviour are changing fast, value chains which have hitherto been separate are linking up to create new solutions, capital markets are driving an enthusiasm for new business models and, last but not least, the state is providing more direction and investment. Read more…

Content Type: Electric Mobility Guide
Authors: Dr.-Ing. Dipl.-Wirt.-Ing. Heiner Hans Heimes, Prof. Dr.-Ing. Achim Kampker M.B.A., M. Sc. Christian Offermanns, M. Sc. Kim D. Kreisköther, Prof. Dr.-Ing. Arno Kwade, M. Sc. Stefan Doose, M. Sc. Marco Ahuis, M. Sc. Peter Michalowski, Dr. Sarah Michaelis, Ehsan Rahimzei, Dr. Sarah Brückner, Karl Rottnick
Publisher: Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University, Battery LabFactory Braunschweig, VDMA, VDMA Waste and Recycling Technology Association

The amount of lithium-ion batteries (LIBs) in their “end of life” (EoL) will increase significantly in the coming years due to the growing market penetration of electric vehicles, which is why new concepts for recycling and raw material recovery must be developed. The process scrap generated in battery production will ensure a need for higher recycling capacities in the near future. To implement sustainable EoL concepts, all players along the value chain from material synthesis to battery cell, battery module, and battery pack production to the use phase must address this issue. Read more…

Content Type: Press Release
Publisher: Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University

The Chair of Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University launches a consortium study titled “Mastering the Challenges of a Batteryʼs Second Life”. Together with numerous industrial partners, the focus is on the question of whether and how aged traction batteries from electric vehicles can be profitably reused as stationary energy storage systems. Learn more…

Content Type: Press Release
Publisher: Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University

Shortly before the updated EU Battery Regulation comes into force, the chair “Production Engineering of E-Mobility Components” (PEM) of RWTH Aachen University has published a study on the European battery recycling market. Due to high investment costs, the current structure of the value chain will move toward large recycling centers, according to the analysis published jointly with “PwC Strategy&”. According to the analysis, after initial overcapacities, the recycling market will be fully utilized from 2030 onwards, requiring investments of more than 2.2 billion euros for the annual processing of around 570,000 tons of battery material. Read more…

Content Type: Research Paper
Authors: Achim Kampker, Heiner Hans Heimes, Christian Offermanns, Merlin Frank, Domenic Klohs and Khanh Nguyen
Publisher: MDPI, Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University

Life cycle strategies for traction batteries, such as remanufacturing, reuse, and recycling of retired automotive lithium-ion batteries (LIBs), have received growing attention, as large volumes of LIBs will retire in the near future and the demand for LIBs continues to grow. At the same time, the relevance of the sustainability of a battery system over its entire life cycle is increasing as factors such as the EU Battery Regulation provide greater market and product transparency. As a result, research and industry require forecasts in order to assess the future market situation and to make well-founded decisions. Therefore, this paper provides forecasts of the return volumes of battery systems from BEVs and PHEVs up to 2035. Additionally, a representative European battery pack for PHEVs and BEVs was evaluated for each year since 2013, based on the ten vehicles with the largest market share in each year until 2021. In addition, the battery return streams are divided into three different 3R strategies based on expert interviews in order to evaluate the upcoming workload in these areas. The term “3R” refers to the sum of the currently existing pathways around reuse, remanufacturing, and recycling. In 2030, about 38.8 GWh will return and enter the recycling process annually. For battery reuse, about 13 GWh will return every year from 2030 onwards, ready to be used in stationary storage for energy transition. Compared to this, battery remanufacturing is expected to be supplied with a slightly lower volume of approximately 11 GWh per year. Read more…

Content Type: Research Paper
Authors: Achim Kampker, Heiner H. Heimes, Christian Offermanns, Moritz H. Frieges, Maximilian Graaf, Natalia Soldan Cattani, Benedikt Späth
Publisher: MDPI, Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University

Mass transport conversion to an electrified powertrain requires suitable strategies for processing electric vehicle (EV) batteries after their intended first service life. Due to aging mechanisms, EV batteries lose capacity over their period of use and become unsuitable for their initial application at some point. However, to expand their lifetime and to meet the sustainability demand for EVs, the usage of these batteries in so-called Re-X applications is under intense discussion. Until now, downstream processing has been subject to high uncertainty regarding the expected advances. While many issues on the technical and ecological side have been at least partially resolved, the economics are still under assessment. For this reason, this paper intends to give a well-based outlook on the costs and benefits of three chosen scenarios: reuse, repurpose, and recycle. It is expected that under the given national policies and global market conditions, growing quantities of retired EV batteries will return from the transportation markets. Consequently, the market potential for retired batteries in downstream applications will significantly increase, as well as calls for stable solutions. Read more…

Content Type: Research Paper
Authors: Achim Kampker, Heiner Hans Heimes, Christian Offermanns, Janis Vienenkötter, Merlin Frank, Daniel Holz
Publisher: MDPI, Production Engineering of E-Mobility Components (PEM) of RWTH Aachen University

Lithium-ion batteries (LIBs) have been proven to be increasingly popular and are the solution of choice for many companies and business models around the world. One major question for battery owners is how to deal with returning batteries if they still contain sufficient capacity for operation. In this case, those energy storages can still be used in different, less-required second-life applications, such as stationary battery storage systems, contributing to increased product sustainability and economic benefits at the same time. However, the second-life business model is still at an early stage of development due to the young EV market in combination with long vehicle lifetimes. As a consequence, there are several barriers in various thematic fields, complicating the rededication process for LIBs. This review paper focuses on a summary of barriers to second-life adoption published with scientific reference. Furthermore, barriers are clustered thematically to provide a transparent landscape picture and valuable insights into the rededication process of LIBs. Read more…

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