SHERLOCK – Systematic and highly precise evaluation of black masses from the recycling of lithium-ion batteries, as well as their processing for optimised and intelligent circular management as part of the funding initiative ‘B@TS’

The project is developing new analytical and characterisation methods that enable precise and reproducible assessment of black mass, an intermediate product of lithium-ion battery recycling. The aim is to define standardised quality grades and to derive concrete recommendations for downstream recycling processes. The work draws on both real industrial black mass and specifically produced model materials with defined properties. These make it possible to systematically investigate the effects of specific impurities and to validate analytical methods in a targeted manner.

Particular emphasis is placed on investigating how contaminants affect direct and hydrometallurgical recycling processes. This will result in a comprehensive set of criteria for assessing black mass, which will in future allow recycling routes to be selected on a process-optimised basis. At the same time, new methods for the targeted removal of impurities are being developed to significantly improve the quality of the recovered raw materials.

Innovative analytical methods play a central role in this work. They enable detailed characterisation of the structural, magnetic and chemical properties of black mass and provide valuable information on its composition, purity, heterogeneity and hazard potential. As a result, material streams can be classified more precisely, assessed in terms of safety and directed towards high-quality further processing.

A key outcome of the project will be a technical specification that defines standardised guidelines for sample preparation, calibration strategies and measurement conditions. SHERLOCK thus lays the foundation for transferable, industrially scalable analytical methods that can be used reliably both in research laboratories and in industrial practice. The specification is also intended to be submitted to DIN and ISO standardisation committees.

In addition, the project is assessing the potential of hybrid recycling process chains that specifically combine direct and hydrometallurgical approaches – including by means of a life cycle assessment (LCA) carried out by Oeko-Institut in accordance with ISO 14040/14044. The aim is to exploit synergies and further increase the efficiency of material recovery.