Fraunhofer IIS Innovates Sensor Technology to Prevent Fires in Recycling Plants Caused by Lithium-Ion Batteries

Fraunhofer IIS Innovates Sensor Technology to Prevent Fires in Recycling Plants Caused by Lithium-Ion Batteries

(IN BRIEF) To address the growing issue of battery fires in recycling plants, researchers at Fraunhofer IIS have developed a groundbreaking sorting system that uses X-ray technology and AI to detect hazardous lithium-ion batteries early in the recycling process. The prototype system, currently undergoing testing, aims to prevent fires by isolating dangerous items before they can cause harm. Set for deployment at LOBBE waste disposal company in 2025, this innovation is part of a larger effort to improve the safety and efficiency of recycling systems.

(PRESS RELEASE) MUNICH, 5-May-2025 — /EuropaWire/ — The rise in improperly disposed of electronic waste, including lithium-ion batteries commonly found in devices such as smartphones and electric toothbrushes, is causing significant challenges in recycling plants. These batteries, often mixed with plastic waste, pose a major risk as they can become damaged and catch fire during the recycling process. In response, researchers at Fraunhofer Institute for Integrated Circuits (IIS) have joined forces with various partners to develop an innovative solution: the DangerSort project, which aims to prevent these hazardous incidents by implementing a sensor-based sorting system.

A report from the German association BDE (Bundesverband der Deutschen Entsorgungs-, Wasser- und Kreislaufwirtschaft e.V.) highlights that over 10,000 fires occur each year in German waste sorting facilities, with around 80% caused by lithium-ion batteries. Improperly disposed batteries, when exposed to the sorting process, are not only fire hazards but also lead to damage estimated at one billion euros annually.

In the DangerSort project, the team is pioneering a new way to tackle these dangers. By combining X-ray technology and artificial intelligence (AI), they have designed a system capable of detecting hazardous lithium-ion batteries at an early stage of the recycling process, well before any fire risks arise. “Our goal is to provide a sensor-driven sorting solution that can identify and isolate dangerous batteries, preventing fires before they happen,” says Johannes Leisner, head of the Sorting and Laboratory Systems group at Fraunhofer IIS. While many plants have adopted firefighting measures, the new technology aims to proactively address the root cause of the fires.

A working prototype of the system has already been developed, showing great promise. The system features a high-speed conveyor belt that moves at speeds of up to three meters per second, with an X-ray source positioned above to scan the waste. The X-ray technology can detect batteries, even when they are concealed within appliances or hidden under other materials. The X-ray images captured are analyzed in real time using an AI system that has been adapted from its use in autonomous vehicles, now optimized to analyze radiographs and pinpoint electrical devices containing batteries.

Once the system identifies a hazardous item, it uses compressed air nozzles to swiftly eject the object from the conveyor belt into a separate chamber. The process requires precise coordination between the timing of image analysis and the ejection mechanism. “One of the challenges we face is identifying various battery sizes, from small button cells to larger e-bike batteries,” Leisner notes.

The system is currently undergoing internal testing at Fraunhofer IIS. In early June 2025, the prototype will be installed at LOBBE, a waste disposal company, for real-world testing. This project, which is supported by funding from the German Federal Ministry of Education and Research (BMBF), is scheduled to continue through August 2025. The system is part of a wider initiative to develop AI applications to create a more sustainable and efficient recycling system for plastic packaging and electronic waste.

Media Contact:

Thomas Kestler
Division Communications
Fraunhofer Institute for Integrated Circuits IIS
Phone +49 911 58061-7611
Fax +49 911 58061-7599
thomas.kestler@iis.fraunhofer.de

SOURCE: Fraunhofer-Gesellschaft