Fraunhofer IFAM Develops Electrochemical Recycling Technology to Recover Lithium and Critical Materials from Battery Waste Streams

© Fraunhofer IFAM
Researchers at Fraunhofer IFAM are developing specialized electrodes that recover valuable metals such as lithium and cobalt from the process water accumulated during battery recycling.

(IN BRIEF) Fraunhofer IFAM is developing an electrochemical recycling process through the MeGaBat project to recover critical raw materials like lithium, cobalt and nickel from battery recycling wastewater. Using specially designed electrodes, the system selectively extracts metal ions and converts them into high-purity materials while recycling water back into the process. Compared to traditional recycling methods, the technology requires less energy, avoids harmful chemicals and can improve efficiency by up to 40 percent. The approach could also be extended to recover rare earth elements from electronic waste, reducing dependence on imports. Currently validated at laboratory scale, the technology is moving toward pilot plant development and is expected to play a role in future sustainable material recovery systems.

(PRESS RELEASE) MUNICH, 1-Apr-2026 — /EuropaWire/ — Fraunhofer IFAM is developing a new electrochemical process designed to recover critical raw materials such as lithium, cobalt and nickel from battery recycling streams, offering a more sustainable and efficient alternative to conventional methods.

As demand for lithium-ion batteries continues to rise—driven by electric vehicles, consumer electronics and energy storage systems—the need for secure and sustainable sources of raw materials has become increasingly urgent. Imports of lithium and other key materials have surged in recent years, underscoring the growing dependency on global supply chains.

To address this challenge, researchers at Fraunhofer IFAM in Bremen are advancing the MeGaBat project, which focuses on recovering valuable materials from process water generated during battery recycling. According to Julian Schwenzel, Head of Electrical Energy Storage, the goal is to enable high-yield, high-purity recovery of raw materials and rare earth elements while helping close material loops and reduce reliance on imports.

The process centers on an electrochemical reactor equipped with specially designed electrodes produced using screen-printing techniques. These electrodes selectively capture metal ions from wastewater, enabling the extraction of substances such as lithium, which can then be recovered as high-purity powders. Cleis Santos, who leads the group for electrochemical recycling processes, explained that the system can be adapted to recover additional materials including cobalt, nickel and copper.

Once the metals are extracted, the treated water is reintroduced into the recycling process, improving overall efficiency. Researchers also envision scaling the technology into multi-reactor systems capable of recovering multiple materials simultaneously within a single facility.

Compared with traditional recycling approaches such as pyrometallurgical and hydrometallurgical processes, the new method operates without aggressive chemicals like acids or bases and requires significantly less energy. This results in lower carbon emissions and improved cost efficiency. Early estimates suggest the technology could enhance overall process efficiency by 30 to 40 percent while delivering higher purity outputs.

The system has already been successfully demonstrated at laboratory scale, and the research team is now working toward a pilot plant to enable industrial deployment. Looking ahead, the technology could also be applied to recover rare earth elements from electronic waste, helping reduce Europe’s reliance on imports of these strategically important materials.

The MeGaBat project, funded by the German Federal Ministry of Research, Technology and Space, will run through 2028. The team plans to showcase a model of the technology at Hannover Messe, highlighting its potential applications not only in battery recycling but also in areas such as seawater desalination and hospital wastewater treatment.

Media Contact:

Martina Ohle
Corporate Communications
Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM
Wiener Strasse 12
28359  Bremen, Germany
martina.ohle@ifam.fraunhofer.de

SOURCE: Fraunhofer-Gesellschaft