Mercedes-Benz battery recycling plant Kuppenheim.

Mercedes-Benz plant Kuppenheim, Germany

Closing the loop with a battery recycling factory.

Mercedes-Benz is building a battery recycling factory in Kuppenheim, Germany, cutting resource consumption and establishing closed-loop recycling of battery raw materials. The groundbreaking ceremony for the project was celebrated in March 2023.

The first stage of the plant mechanical separation - starts operations in spring 2024. Subject to the outcome of promising discussions with the public sector, a hydrometallurgy pilot plant will be established by mid 2024. This innovative approach for an integrated recycling concept within a single factory is currently unique in Europe. Mercedes-Benz is investing a double-digit million Euro amount in the construction of the net carbon-neutral plant, which is funded by the German Federal Ministry of Economics and Climate Protection as part of a scientific research project. This investment strengthens the role of the Kuppenheim site within the global Mercedes-Benz production network and marks a decisive step for Mercedes-Benz's sustainable business strategy.

Jörg Burzer, Member of the Board of Management of Mercedes-Benz Group AG. Production & Supply Chain Management.

With a recycling rate of more than 96 percent, a 'mine of tomorrow' is being created here in Kuppenheim. The innovative technology approach enables us to incorporate the valuable raw materials into new electric vehicles. We are consistently expanding our expertise of the battery value chain and are taking an important step in our sustainability business strategy. Together with our partners from industry and science, we are demonstrating the potential of Baden-Württemberg and Germany to innovate in the area of sustainable electromobility.

Jörg Burzer
Member of the Board of Management of Mercedes-Benz Group AG, Production, Quality and Supply Chain Management
Jörg Burzer, Member of the Board of Management of Mercedes-Benz Group AG. Production & Supply Chain Management.

Circular battery economy: Recovery rate of more than 96 percent

The Mercedes-Benz battery recycling factory in Kuppenheim will cover every step from shredding of battery modules to drying and processing of battery-grade materials. The hydrometallurgy process with a recovery rate of more than 96 percent enables a true circular economy of battery materials. Mercedes-Benz is cooperating with technology partner Primobius (joint venture of the German mechanical engineering company SMS group and the Australian project developer Neometals). As part of the overarching scientific research project, the entire process of battery recycling is also taken into account: From the development of logistics concepts, through the sustainable recycling of valuable raw materials, to the reintegration of recyclates into the production of new batteries. Thus the partners are making an important contribution to the future scaling of the battery recycling industry in Germany.

The pilot plant is expected to have an annual capacity of 2,500 tonnes. The recovered materials will be fed back into the recycling loop to produce more than 50,000 battery modules for new Mercedes-Benz models. Based on the findings of the pilot factory, production volumes could be scaled up in the medium to long term.

Location Mercedes-Benz plant Kuppenheim
Area 7.000 sqm
Ramp-up mechanical dismantling Summer 2024
Annual capacity 2,500 t
Batteries Lithium-ion batteries from (plug-in) hybrid and electric vehicles
Origin of the batteries Test vehicles, start-up batteries, possibly returns from the field
Technology Mechanical-hydrometallurgical process
Recovery rate > 96%
Recovered material Battery-grade recyclate (cobalt, nickel, lithium and in future also graphite)
Technology partner Primobius GmbH
Scientific partners Karlsruhe Institute of Technology
Technical University of Berlin
Technical University of Berlin

Holistic approach to battery value creation

Mercedes-Benz is taking a holistic approach to the circular economy of battery systems, looking at three core issues: Circular design, value retention and closing the loop. During the development of a vehicle, the company creates a concept for each vehicle model in which all components and materials are analyzed for their suitability in the context of a circular economy. Material recycling of the raw materials used, such as lithium, nickel, cobalt, is an integral part of this approach, and also begins with the design of the components. This approach covers the entire supply chain from mining to recycling. A high level of attention is also paid to the observance of human rights in the working conditions of employees. Mercedes-Benz offers reconditioned batteries as replacement parts for all electric vehicles, in order to comply with the idea of a closed economic loop and to conserve resources. In addition, Mercedes-Benz has established a successful business model with stationary large-scale energy storages through its subsidiary Mercedes-Benz Energy. Batteries that can no longer be used in vehicles can continue to be used in a 2nd-life storage system. Material recycling is at the end of a battery's life, and is the key to closing the loop of recyclable materials.

Groundbreaking battery recycling plant Kuppenheim.
Groundbreaking battery recycling plant Kuppenheim.

This article was last updated in March 2024.