Breaking the "Black Mass Challenge": European Company Achieves Tonne-Scale Battery Graphite Recycling

Overcoming Technical Bottlenecks: Hydrometallurgical Innovation Revolutionizes Graphite Recycling Pathways

MUNICH – February 13, 2025 – Tozero, a European pioneer in sustainable lithium-ion battery recycling, announced an industry breakthrough: the successful large-scale production of battery-grade recycled graphite and the first-ever use of 100% recycled anode material in commercial battery cells. This milestone not only validates the commercial viability of recycled materials but also overcomes the long-standing challenge of balancing economic feasibility with environmental sustainability in traditional recycling technologies.

Conventional recycling methods, which rely on strong acid corrosion, often lead to the loss of graphite resources. Tozero’s hydrometallurgical process eliminates hazardous reagents. At its pilot plant, which began operations in 2023, the company has achieved a graphite recovery rate of over 80% through an innovative process, preserving the material’s morphological structure. After purification, the performance of the recycled graphite matches that of virgin material. Adham Raslan, Head of Technology, explained the key to success: "Through process optimization, we are truly enabling the circular economy for this 'black gold'."

Green Production Capacity: Driving Towards Tonne-Scale Goals with a Circular Economy

Building on this technological breakthrough, Tozero plans to achieve an annual production capacity of 2,000 tonnes by 2027 and surpass the 10,000-tonne threshold by 2030. Its process can treat any pretreated battery waste (black mass), directly producing the ultra-high-purity material required by battery manufacturers, while reducing emissions by 70% compared to mining. The company is currently collaborating with suppliers from over 10 countries to build a localized circular network, reducing Europe‘s dependence on imported graphite.

Data shows that the EU’s graphite demand will surge 20 to 25-fold by 2040, with 98% currently reliant on imports from China. A global supply gap of 800,000 tonnes is expected by 2030. Tozero‘s capacity expansion plans aim not only to fill this gap but also to help automakers comply with the EU Battery Regulation and carbon neutrality targets. CEO Sarah Fleischer emphasized: "Graphite accounts for 40% of a battery's carbon footprint and urgently needs a sustainable solution. Our breakthrough proves that a circular economy can simultaneously ensure supply chain security and deliver environmental benefits."

Source: batteriesnews