Regeneration of graphite from recycled graphite batteries for Li-ion batteries and other applications by post-treatment of purified graphite

PROJECT COST:

679 520 $

PRIMA CONTRIBUTION:

475 664 $

PROJECT DETAILS:

Building on the GraphRenew-MCS001 process, which allows the purification of graphite from Li-ion battery black mass to a carbon purity above 99.95 wt%, this project focuses on the regeneration of recycled and purified graphite through post-treatment processes. The goal is to enable its reuse as battery-grade graphite for Li-ion applications.

Post-treatment is necessary because defects are introduced during battery operation and during the recycling process. Without regeneration, purified graphite cannot be effectively reused in high-value applications, which would limit the benefits of recycling and reduce the impact of the circular economy.

To correct these defects and reach performance levels comparable to natural battery-grade graphite, the post-treatment will target improvements in key properties such as BET surface area, particle size distribution, density, and electrochemical performance in Li-ion cells.

A techno-economic analysis will also be performed to evaluate the advantages of recovering, purifying, and regenerating graphite from recycled batteries compared with the use of mined natural graphite.

The expected benefits for the electric vehicle industry, Li-ion cell and battery manufacturers, and battery recyclers are significant, as value-added reuse of recycled graphite is not yet technically or economically feasible at large scale.

More than ten international Li-ion battery recyclers have expressed interest in following and supporting GGT’s GraphRenew activities, including Lithion and GreenLIB. In particular, the recovery and reuse of graphite from Li-ion batteries without nickel and cobalt (e.g., LFP batteries) is essential to improving the economic viability of Li-ion battery recycling and strengthening the circular economy.

KPM-Qc, which is also involved in this project, aims to establish itself as a center of expertise in battery-grade graphite. Most laboratory- and pilot-scale purification, post-treatment, and characterization work will be carried out at its new facilities in Montréal. For GGT, this project represents an important step toward the demonstration and commercialization of the GraphRenew process.