Fraunhofer Institute for Ceramic Technologies and Systems IKTS
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BALU The BALU project aims to develop sustainable and cost-effective aluminum-ion batteries (AIBs) as an alternative to lithium-based systems, addressing material availability challenges and rising costs in energy storage. With the goal of achieving Technology Readiness Level (TRL) 6, the project focuses on creating recyclable cell concepts and scaling manufacturing processes to pilot production. Fraunhofer IKTS brings extensive expertise in electrode processing, coating, and calendering for battery technologies, including lithium-ion and aluminum-ion cells. Our capabilities span lab-scale coating on A5 substrates to roll-to-roll manufacturing of meter-long electrodes. In Freiberg, electrode materials can be processed under dry room conditions, with facilities for assembling pouch cells and characterizing electrochemical performance. Current initiatives include advancing pouch cell assembly tools for multilayer designs and contributing to recyclable cell design. The Aluminum-Graphite Dual-Ion Battery (AGDIB), central to BALU, has demonstrated excellent lab-scale performance, including energy densities of up to 135 Wh/kg, power densities up to 9000 W/kg, and over 20,000 cycles. BALU addresses key challenges such as developing cost-efficient current collectors, corrosion-resistant cell casings, and scalable production techniques. Grant agreement Nº: 03XP0567A
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NEO-Cycle In NEO-CYCLE project, the aim is to sustainably upcycle used NdFeB magnets from hard disk drives (HDDs) for environmentally friendly applications in industries such as pharmaceuticals, ammonia, fertilizers, and polymers. By advancing processes to a TRL6 level, IKTS contributes its expertise in advanced monitoring and sensing technologies. IKTS analyses data and sets robust target values, considering the impact of deviations on production quality. IKTS also leads the selection of sensors and metrology for each process stage and ensures precise monitoring and control, leveraging insights from existing studies and best practices. Additionally, IKTS defines sensor integration points within the upscaled pilots, including an electrochemical cell and SSC process. This work underpins the NEO-CYCLE project’s goal of delivering sustainable and efficient upcycling solutions for the EU. Grant agreement Nº: 101138058
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A revolutionary approach for maximising process water reuse and resource recovery through a smart, circular and integrated solution Fraunhofer IKTS is driving sustainable innovations in the paper industry through its work on the R3VOLUTION project at the Felix Schoeller Mill Weißenborn. By optimizing water and energy management, IKTS tackles challenges in wastewater treatment and energy recovery to reduce environmental impact. Key efforts include predictive pH control in wastewater treatment, using data-driven models to stabilize pH and improve biological treatment while reducing chemical use. Additionally, it explores thermal energy recovery from wastewater discharge, optimizing cooling processes to meet strict environmental regulations and recycle waste heat. Through the R3VOLUTION initiative, IKTS supports revolutionary industrial water management in the EU, aiming for over 90% water reuse and significant resource recovery. These innovations help cut freshwater consumption, energy usage, and waste, advancing sustainability in paper production. Grant agreement Nº: 101138245
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SkaleD Scaling up extrusion-based direct coating The project consortium, coordinated by EAS Batteries, is optimizing and scaling the direct extrusion process and the associated plant concepts from the pilot to the industrial scale. Fraunhofer IKTS is working on environmentally friendly formulations and the proof of concept for the simultaneous and double-sided coating of electrodes using direct extrusion. This project builds on the progress of the earlier projects “OptiEx” and “Headline” and focuses on scaling up the innovative direct extrusion technology to enable mass production. The electrodes are then used to manufacture prototype lithium-ion cells. Grant agreement Nº: 03XP0631A-D
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