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At IME, a new project funded by the BMWK is currently being carried out. The RISE project (Recycling of Hydride Storage and Sorption Materials for Sustainable Hydrogen Storage) is being conducted in collaboration with ThyssenKrupp Marine Systems, Fraunhofer IFAM, and GfE. The name already indicates that it concerns the recycling of retired hydrogen storage alloys. The focus of the investigations is on manganese-titanium-based alloys. These storage alloys were developed and brought to market maturity at the end of the last century, so they have been in use in specialized vehicles for several decades. For technical reasons, however, the service life of these storages is limited. While approaches to give these storages a second life are promising, there remains a necessity to ultimately develop and implement strategies for recycling. During use, the storage alloy is housed in steel cylinders. During filling and emptying with hydrogen, the alloy undergoes expansion and contraction. Over its entire lifecycle, this leads to the pulverization of the alloy. The extremely high reactive surface area resulting from this causes oxidation of the alloy upon opening the cylinder to be unavoidable so far. The aim of IME within the framework of this research project is to remelt the partially oxidized material in a vacuum induction furnace with the addition of deoxidizing agents. The challenge lies in developing a suitable setup that can withstand both the thermochemically aggressive melt and the deoxidizing agent. Subsequently, the actual recycling process or procedure will be designed. Additionally, it is being considered to hydrometallurgically process any slag containing rare earth elements that may arise during the process. The melting processes will initially take place on a laboratory scale. After successful setup and process development, implementation will occur on a pilot and industrial scale.

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Congratulations to our colleague Dr. Srećko Stopić on receiving the Outstanding Reviewer Award once again! Following previous recognitions for his exceptional reviewing contributions to the journals Metals (2020) and Crystals (2023), he has now also been honored for his work with Materials (2024) – all published by the MDPI publishing house in Switzerland. With this award, MDPI recognizes particularly dedicated reviewers who stand out through their thorough, reliable, and timely evaluations. Dr. Stopić is active not only as a reviewer but also as an editor and co-author. For over 25 years, he has played a key role in shaping research at the IME and has supported numerous colleagues and students throughout the years. At the institute, he is known not only for his commitment but also for his extensive international network: from research collaborations with scientists in Côte d’Ivoire, to environmental projects tackling hazardous red mud in Bosnia, all the way to academic exchange programs with his home country of Serbia. Throughout his scientific career, he has published over 250 works, including four academic books. We warmly congratulate Dr. Srećko Stopić on this well-deserved award and thank him for his many years of valuable contributions to the institute! A press release has also been published on the official RWTH website. It can be accessed via the following link:

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Link: https://www.rwth-aachen.de/cms/root/die-rwth/aktuell/pressemitteilungen/maerz-2025/~bmgdan/torjaeger-in-der-wissenschaft-und-forsch/?lidx=1

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Recently, together with our partners from Gebrüder Lödige Maschinenbau GmbH and the Öko-Institut e.V., we held the kick-off meeting for the ProMotion project at IME. In this project, we are jointly developing an innovative prototype reactor featuring a novel Ploughshare® mixer to improve the recycling of lithium-ion batteries and make the process more efficient and sustainable. The aim of the project is to significantly optimize the recycling process and thereby increase the recovery rates of critical raw materials such as lithium, as well as other valuable metal-containing compounds. As battery waste is expected to rise sharply in the coming years, finding better recycling solutions is more important than ever. The targeted process step usually follows the deep discharge, disassembly, and mechanical shredding of the battery cells. The focus is on thermal pre-treatment, which removes organic components and simultaneously generates soluble lithium compounds that can later be more easily separated. This pre-treatment also has a positive effect on subsequent hydrometallurgical processes—particularly due to improved wettability and a finer particle structure of the black mass. The new process aims to recover as many valuable raw materials as possible—such as lithium, nickel, and cobalt—while also significantly reducing environmental impact.

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The kickoff meeting for the second funding period of our DFG project priority program “Engineered Artificial Minerals” (EnAM) was conducted in Fulda. The event commenced with a welcome address by Prof. Peuker (MTVAT TU Freiberg), followed by presentations from each project team. These teams provided a summary of their accomplishments during the first funding period and outlined their objectives for the upcoming phase. In this second funding period, the primary focus of the central project is on the generation of slag from model systems that can yield sufficient slag material to support projects involved in subsequent processing steps. This central initiative will also entail the development and provision of 3D geo-metallurgical characterizations of the slags, along with supporting other projects through geo-metallurgical data. Within the project B8, which IME coordinates, we are engineering tantalum-rich mineral phases derived from recycling slags associated with waste electrical and electronic equipment (WEEE) through fluxes modification, controlled cooling and segregation. During this second phase of funding, we aim to generalize our investigations and process models and consider the applicability of their correlations to more than one slag system.

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We are pleased to announce the colloquiums aimed at selecting a new university professor (W2) with Tenure Track for our IME Process Metallurgy and Metal Recycling. The new professorship will work alongside Professor Friedrich until his retirement at IME, focusing on battery and electronics waste recycling. Once the Tenure Track phase is completed, full leadership of the institute will be transferred. This event will provide candidates with the opportunity to present their research and teaching concepts. For detailed information regarding the colloquium, including specific dates, times, and candidate profiles, please refer to the attached announcement. We invite faculty members, students, and all interested parties to attend this important event.

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PDF file: Ankündigung Announcement_1738857989.pdf

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IME is proud to announce that we have recently reached the significant milestone of 1,000 research contributions over the past 25 years! This achievement reflects the dedication, creativity, and collaborative efforts of our researchers, students, technicians, and administrative staff. Over the past quarter century, our work has spanned diverse aspects of metallurgy: from nanoparticles to battery recycling, from slag design to hydrogen applications and metal purification, we remain attentive to emerging challenges and continuously foster a more sustainable and green future of metallurgy. Whether in pyrometallurgy, hydrometallurgy, electrochemistry, or beyond, our institution strives to advance knowledge and develop innovative solutions. The scope of these 1,000 publications underscores our collective impact and includes (for example):

• 430 Research Articles
• 251 Conference Papers
• 185 Presentations
• 82 Posters
• 18 Patents

We extend our deepest gratitude to everyone who has played a role in this journey. A special thank goes to our research partners from all around the world for their invaluable cooperation and collaboration, which helped make these contributions possible. We look forward to continuing our mission of advancing knowledge and fostering innovation in the years to come. We invite you to view our scientific contributions at the following link:

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Link: www.researchgate.net/profile/Bernd-Friedrich-2

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Shortly before Christmas, the Montanuniversität Leoben in Austria awarded Professor Bernd Friedrich an honorary doctorate. In the left picture, you can see Professor Peter Moser, Rector of the Montanuniversität Leoben, and Professor Helmut Antrekowitsch, Vice Rector for Research and Sustainability, on the left and right side of Prof. Bernd Friedrich. With this distinction, the Austrian university recognizes his significant scientific contributions as well as his longstanding commitment to fostering young researchers. 25 years ago, Professor Friedrich revitalized the collaboration with the Lehrstuhl für Nichteisenmetallurgie (Chair of Non-Ferrous Metallurgy) at the Montanuniversität Leoben. Together with colleagues from Leoben, he initiated the annual Young Researcher Workshop for Non-Ferrous Metallurgists, also known as the “Aachen-Leoben Workshop.” This format has fostered a close partnership and intensive scientific exchange. The collaboration extends far beyond the workshop: in addition to promoting academic exchange among doctoral candidates, the two chairs of non-ferrous metallurgy work closely together in EU projects and teaching activities. Together, they address current challenges, such as enhancing the attractiveness of study programs, fostering young talent, and securing the economic sustainability of the field. We extend our heartfelt congratulations to Professor Friedrich on this honor! A special thanks goes to all those who have shaped and sustained this close collaboration. We look forward to a continued successful partnership between the two chairs of non-ferrous metallurgy. Details of the Honorary Doctorate: The Montanuniversität Leoben grants, based on the decision of the Senate from October 23, 2024, on the recommendation of the Rector, Univ.-Prof. Dipl.-Ing. Dr.mont. Dr.-Ing.E.h. Dr.h.c. Peter Moser, to Prof. Dr.-Ing. Dr.h.c. Bernd Friedrich, pursuant to the University Act of 2002 in conjunction with the statute section “Granting of Academic Titles and Honors,” the title and dignity of Doctor of Montanistic Sciences honoris causa, in recognition of his outstanding merits for the Montanuniversität Leoben. Leoben, December 20, 2024 The Rector: Univ.-Prof. Dipl.-Ing. Dr.mont. Dr.-Ing.E.h. Dr.h.c. Peter Moser This news has also been featured in the Montanuniversität Leoben newsletter, available at the following link:

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Link: www.unileoben.ac.at/news/akademische-feier-11/

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This Special Issue brings together 24 insightful articles, offering a deep dive into the latest advancements in battery recycling. The collection explores the essential conditions for recycling efficiency, covering various battery types and processes step by step. Key topics include:

• Innovative Sorting Methods: Studies highlight the use of air classifiers to separate battery foils and advanced sensors for sorting materials by type, boosting the precision of recycling processes.
• Thermal Pretreatment: Thermal pretreatment on materials like NMC 622 black mass emerges as a critical step in removing organic compounds and breaking down materials. This enables easier and more effective recovery of valuable components. Researchers also explore techniques such as sulfuric roasting for LCO-rich black mass and methods for safe lithium recovery from LiS cells.
• Hydrometallurgical Advances: After pretreatment, hydrometallurgical processes recover valuable elements like lithium, cobalt, and nickel. Studies explore eco-friendly options, such as organic acids (e.g., gluconic and acetic acids), to enhance efficiency while minimizing environmental impact.

In addition to these technical advancements, the Special Issue offers broader perspectives, addressing topics such as the role of lithium-ion batteries (LIBs) in sustainable energy and strategies to reduce material losses during recycling. This Special Issue is now available for purchase at the following link:

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Link: www.mdpi.com/books/reprint/10197-new-science-based-concepts-for-increased-efficiency-in-battery-recycling-2023

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A new DFG research project has been launched at IME in which a scientific methodology is being developed and evaluated that enables the targeted synthesis of technical secondary raw materials from metallurgical residues and fine ceramics to be recycled as additives. As an application case, fayalitic by-products and ceramic processing residues are to be investigated as secondary resources for the synthesis of ceramic particles with specific thermal, optical and structural properties. The synthesized ceramic particles will be used as heat transfer and storage media in solar power plants in the future. The properties will be compared with those of ceramic particles produced from unmodified raw materials according to the state of the art in order to evaluate the new method. In addition, thermodynamic modelling and experimental results will be combined to validate the hypotheses of this research and to develop a generalized, integrated model workflow for the conversion of metallurgical by-products into ceramic particles with application-specific properties.

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Link: www.metallurgie.rwth-aachen.de/#/research/project/176

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Prof. Dr. Ing. Friedrich was able to record a new podcast with Mr. Voss on the topic of aluminium recycling. The aluminium recycling industry is currently confronted with a huge amount of new aluminium scrap, which is often contaminated with plastics, unwanted metals or ceramics. This creates a high demand for suitable and economically viable refining options. As a result, new questions arise in research, such as the approach of universities like RWTH Aachen University in this area, the control of relevant impurities as well as existing industrial practices and promising future technologies. There is also the question of the need for multiple processes or a single solution for all contaminants. We would also like to thank the AMAP (Aachen Center for Metal and Alloy Processing) for their support in realising this podcast. The complete podcast is available at the following link.

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Link: creators.spotify.com/pod/show/simon-vo/episodes/47-Aluminum-Recycling-for-a-Circular-Economy—Prof–Bernd-Friedrich-e2r3udt

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We would like to congratulate Otto-Junker on its 100th anniversary. As a world-leading provider of industrial furnace systems for melting, heat treatment, and recycling, Otto-Junker has been supporting educational and research institutions for many years through its foundation. The foundation supports numerous research projects, including at the IME, which not only enable scientific progress but also sustainable solutions to current challenges. As part of a research project funded by the Otto Junker Foundation, a new plant for the pyrolysis of battery cells and modules was successfully put into operation at the IME recently. This plant is used to investigate the upscaling of battery pyrolysis for both cells and entire modules. The findings on battery pyrolysis gained on a laboratory scale can now be transferred to large numbers of cells and entire modules for further research. We look forward to continuing our successful collaboration with Otto Junker and the Otto Junker Foundation and wish Otto Junker every success in the future.

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Link: www.otto-junker.com/de/unternehmen/100-jahre-otto-junker/

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We are pleased to present our anniversary video, which provides insight into the celebrations marking the 125th anniversary of our institute and the 25th anniversary of Prof. Dr. Ing. Friedrich. A heartfelt thank you goes out to all speakers and guests who enriched this special occasion with their inspiring words and presence. Your support and appreciation means a lot to us. Enjoy watching!

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Link: www.youtube.com/watch?v=PKJ8tmUgLpU

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We are pleased that Wacker AG has given us the opportunity to present our research on Electro-Slag Remelting (ESR) at this year’s conference in Burghausen. There has been a close collaboration for 20 years in the research of the properties and applications of ESR slags, as well as other pyrometallurgical processes. Together with Richard Schneider (ESR of copper alloys) and Hugo Lucas (modeling of thermophysical properties), a strong team from the IME, led by Prof. Dr. Ing. Friedrich, was represented in Burghausen.

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Link: www.wacker.com/cms/en-us/insights/esr.html

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Our institute is celebrating its 125th anniversary as well as the 25th service anniversary of our institute’s director, Prof. Dr. Ing. Friedrich. Founded by Wilhelm Borchers, we have developed under the leadership of Prof. Dr. Ing. Friedrich into a leading research center for sustainable metal recycling. In this context, we would like to thank all employees, students, and partners for their support and cooperation. With numerous international collaborations and successful spin-offs, we play a central role in raw material supply and sustainable economy. Together, we look back on 125 years of research and innovation and look forward to a continued successful future.

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The book on the last 25 years is available here.

Find out more about the 125th anniversary here

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On 11th April, Prof. Friedrich gave a keynote on the Advanced Battery Power Conference in Münster. He gave an overview of the last 20 years of battery recycling research, its drivers and requirements, as well as the many unresolved issues and challenges to be addressed in future works. As the conference offers a large stage for the battery production community, this was a special opportunity to discuss the challenges to be addressed after the battery lifetime from the perspective of recyclers.

Prof. Friedrich also moderated the session on life-cycle and recycling. It is clear that the topic of recycling has become an integral part of lithium-ion battery research. This was also evident in the insightful conversations, intensive discussions, and the exciting exchange during the conference.

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Link: https://battery-power.eu/