Sustainable Graphite Regeneration for Battery Recycling- ReGraph

ReGraph is a research project addressing a key challenge in the rapidly expanding European battery value chain: the need for resource-efficient and circular management of graphite from lithium-ion batteries. Graphite constitutes approximately 12–21 wt.% of lithium-ion batteries and is classified as a critical raw material by the EU, yet it is currently recovered only to a very limited extent.

Through systematic studies on separation, purification and regeneration of graphite from graphite-rich fractions generated during battery recycling, ReGraph generates new knowledge and process foundations enabling the reuse of graphite in new batteries. The project combines extensive material characterization, thermodynamic modelling, hydro- and pyrometallurgical laboratory studies, and electrochemical evaluation in battery cells.

Background

Lithium-ion batteries are essential for the electrification of transport and the expansion of renewable energy systems. The EU Battery Regulation sets ambitious targets for battery recycling, including high recovery rates for metals such as cobalt, nickel, copper and lithium. However, graphite – the dominant anode material – is not subject to equivalent recovery requirements and is often consumed in pyrometallurgical processes or lost in residual streams.

At the same time, the demand for battery-grade graphite in the EU is expected to reach several hundred thousand tonnes per year within the coming decade. Primary graphite production is energy-intensive and associated with significant environmental impacts. Regeneration of graphite from end-of-life batteries therefore offers substantial potential to reduce climate impact, strengthen EU self-sufficiency in critical raw materials, and improve circularity in the battery value chain.

Purpose and goals

The overall objective of ReGraph is to enable the production of battery-grade graphite from graphite-rich fractions generated during recycling of whole lithium-ion batteries.

The project aims to:

• Build knowledge on the characteristics of graphite-rich fractions from mechanical and hydrometallurgical battery recycling.
• Develop and optimize purification methods to achieve graphite purity of ≥99.9% carbon.
• Develop energy-efficient thermal regeneration methods to restore the graphite crystal structure.
• Demonstrate that regenerated graphite can achieve electrochemical performance comparable to virgin graphite in coin-cell tests.
• Assess the technical, economic and environmental feasibility for future upscaling and industrial implementation.

Implementation

ReGraph is carried out in close collaboration between the project partners and applies an integrated approach covering the full chain from various type of feed materials (linked to NMC and LFP batteries) to validated graphite product.

The work includes:

• Improved mechanical processing and separation to obtain graphite-rich fractions.
• Comprehensive material characterization (e.g. chemical composition, crystal structure, particle properties).
• Hydrometallurgical purification of graphite with a focus on high purity and low chemical consumption.
• Thermal treatment for regeneration of the graphite structure at the lowest possible temperature and energy demand.
• Electrochemical testing of regenerated graphite in lithium-ion battery cells.
• Techno-economic analysis and environmental assessment based on experimental data.

Project Partners

• Luleå University of Technology – Process Metallurgy at LTU is project coordinator also responsible for material characterization, thermodynamic modelling, and hydro- and pyrometallurgical laboratory studies, including graphite regeneration and evaluation.
• Greenavance Tech Global AB (GAT) – Has a team of professionals with extensive expertise in research and development, process development, industrialization, and scaling up operations for battery recycling. GAT contributes mechanical recycling, industrial process perspectives, electrochemical testing, and environmental and techno-economic assessments.