Closed-loop recycling - Nickelhütte Aue GmbH

We close the loop: From recycling and processing of all materials to high-quality raw materials for new batteries.

With our closed-loop recycling, no material is wasted. Batteries, black mass, secondary streams, and production residues are fully processed and fed back into the production of new batteries. While other service providers stop after mechanical processing or ship materials abroad, we offer an all-in-one stop solution - efficient, local, and resource-conserving. Thus, raw materials remain within the European circular economy, strengthen the raw materials market, and meet the requirements of the EU Critical Raw Materials Act (CRMA).

What does closed-loop recycling mean?

Closed-loop recycling means, that all materials, there included batteries, black mass, secondary streams, and production residues, are fully processed and fed back into the production of new batteries. Through recycling of critical raw materials and thanks to our hydrometallurgical processes, which have been refined and optimized over centuries, no waste products are generated.

Which materials can be processed?

Our closed-loop recycling covers batteries and accumulators of all sizes, black mass, secondary streams, and production waste from cell manufacturing. All materials are professionally treated and fed back into the production cycle.

Why is closed-loop recycling important?

Closed-loop recycling is a key element of a sustainable and independent battery production. While returning all raw materials into the production cycle, the reliance on virgin raw materials is reduced and an independent European value chain is created. Our method generates no waste materials, ensures that resources are fully utilised, and significantly reduces CO₂ emissions. Thereby, we actively contribute to a circular economy being efficient, environmentally friendly, and built for the future.

The three steps of our closed-loop recycling process

Our recycling process consists of three main steps, enabling efficient, safe, and resource-conserving battery recycling:

1. Thermal deactivation

At first, batteries are thermally pre-treated to minimize potential risks and to bring them into a form suitable for further processing. Part of the required energy is sourced directly from the batteries themselves, supplemented by high-calorific, CO₂-neutral waste. Waste gas is efficiently cleaned, and waste heat is used internally and additionally supplied to the district heating network of the city of Aue-Bad Schlema.

2. Mechanical treatment

After thermal treatment, the material is mechanically processed. Coarse metal fractions such as steel, copper, and aluminium are separated and returned to the material cycle as scrap. At the same time, a concentrate is produced that forms the basis for the hydrometallurgical refining afterwards.

3. Hydrometallurgical refining

Finally, the metal powder, obtained from mechanical treatment, is refined by hydrometallurgical processing. By multiple leaching, purification, and crystallization steps, high-quality products such as nickel, cobalt, copper, and lithium salts are produced, that are fed back into the production cycle of new batteries..

Recycling+

We go beyond conventional battery recycling - from black mass to new raw materials – under one roof.

One-stop solution

All services from a single source - no long transport routes, just efficient, local processing.

Experience

We rely long-term business relationships, tradition, and progress since 1635.

While residual byproducts without further treatment are often recycled thermally, most recyclers resell black mass – often to non-EU countries. However, thanks to our closed-loop recycling, we can completely recycle and refine both residual streams and black mass, thereby recovering valuable raw materials to produce new batteries and accumulators and contribute to a strong European economy at the same time.

Yes, our closed-loop recycling is particularly environmentally friendly. All valuable raw materials are completely recovered and remain in the European circular economy, which, in turn, significantly reduces both raw material consumption and CO₂ emissions.

All our recycling processes are closed-loop. Thus customers benefit from complete recycling without additional costs.