Closed-loop recycling - Nickelhütte Aue GmbH

We close the loop: From recycling through refining all materials to high-quality raw materials for new batteries.

With our closed-loop recycling approach, no material goes to waste. Batteries, black mass, residual streams, and production waste are fully processed and reintroduced into the production of new batteries. While other providers stop after mechanical treatment or export materials abroad, we offer an all-inclusive, single-source solution - efficient, local, and resource-conserving. As a result, 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?

In closed-loop recycling, all materials—batteries, black mass, residual streams, and production waste -are fully refined and fed directly back into the production cycle of new batteries. By recycling critical raw materials, no waste products are generated. This is only possible thanks to our hydrometallurgical processes, which have been refined and optimized over centuries.

What materials can be processed?

Our closed-loop recycling covers batteries and accumulators of all sizes, black mass, residual 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 sustainable and independent battery production. Returning raw materials to the production cycle reduces dependence on primary resources and supports an independent European value chain. Our approach generates no waste materials, ensures full resource utilization, and significantly reduces CO₂ emissions. In this way, we actively contribute to an efficient, environmentally friendly, and future-proof circular economy.

Our closed-loop recycling process in three steps

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

1. Thermal deactivation

Batteries are first thermally pre-treated to minimize potential risks and make them suitable for further processing. Part of the required energy is generated directly from the batteries themselves, supplemented by CO₂-neutral, high-calorific waste. Exhaust gases are efficiently cleaned, and waste heat is used internally and fed into the district heating network of Aue-Bad Schlema..

2. Mechanical treatment

Following thermal treatment, the material is mechanically processed. Coarse metal fractions such as steel, copper, and aluminum are separated and returned to the recycling cycle as scrap. At the same time, a concentrate is produced that serves as the basis for subsequent hydrometallurgical refining.

3. Hydrometallurgical post treatment

In the final step, the metal powder obtained from mechanical processing is refined hydrometallurgically. Through multiple leaching, purification, and crystallization processes, high-value products such as nickel, cobalt, copper, and lithium salts are recovered and directly reintroduced into the production cycle of new batteries.

Recycling+

We recycle and upcycle used batteries into new raw materials - entirely in-house.

One-stop solution

All services in one place: no long transport routes, just efficient, local recycling.

Experience

We rely on tradition, progress, and long-standing business relationships dating back to 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.