The BMW Group is building a Cell Recycling Competence Centre (CRCC) for battery cells in Kirchroth, in the Straubing-Bogen district of Lower Bavaria, Munich. The company’s plan is to implement a process referred to as “direct recycling” in which residual materials from battery cell production, as well as whole battery cells, are to be mechanically dismantled into their valuable components. The recovered raw materials are then directly reused in pilot production of battery cells at the company’s own Battery Cell Competence Centres.
Battery cell raw materials – primarily lithium and cobalt, but also graphite, manganese, nickel and copper – are among the most costly parts of cell production. Responsible use of these resources is essential from both environmental and economic perspectives. “The direct recycling will help reducing the costs for our battery cell pilot line,” explained Markus Fallböhmer, SVP Battery Production at BMW AG.
Unlike conventional methods, the main characteristic of direct recycling is that raw materials from battery cells are not reverted to their original state but are instead fed back “directly” into the cell production cycle. Once the processes are finalised, battery cell material in the mid-double-digit tonne range can be recycled per year.
The new CRCC, spanning an area of 2,200 m², will be integrated into the expansion of an existing building in the Kirchroth-Nord industrial park, near Straubing. Electrical energy from the discharged cells will be captured in energy storage systems within the building and used to operate the recycling systems. The energy supply will be augmented by photovoltaic systems installed on the roof of the building.
While the intellectual property for the recycling method is fully owned by the BMW Group – the Competence Centre will be built and operated by Encory GmbH. As a joint venture of the BMW Group and Interzero Group, Encory develops and implements logistics and consulting solutions in areas such as collection, recycling, and remanufacturing of vehicle components. Both partners hold a 50% stake in the company. Around 20 people will be employed in the new Competence Centre.
BMW has identified a circular economy as one of its key issues in designing more resource-efficient vehicles, showcased by its i Vision Circular environmental car concept. The premise of circular economy is to optimize the circularity of materials, meaning resources are not lost but retain their value for long-term use.
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