AFRY and Stena Recycling have designed a large-scale recycling plant for electric car batteries in Halmstad, Sweden

Implementing sustainable solutions: front-end engineering for repurposing electronic waste

Stena Recycling invested in a new battery recycling process in Halmstad, Sweden, to address the need for sustainable and environmentally friendly solutions for used batteries. AFRY engineers have designed the lifting table, transport wagon, and de-charging stations, contributing to the complete system set-up that will recycle electrical lithium-ion car batteries.

The client and what they needed

The client is Stena Recycling, and the project is located in Halmstad, Sweden. In 2021, Stena Recycling decided to invest a quarter of a billion SEK in a new battery recycling process. The investment will make it possible to recycle 95 % of a lithium-ion battery, which is the most commonly used battery in electric vehicles.

The background

The use of electric cars is increasing significantly, which has led to a growing need for a sustainable and environmentally friendly recycling process for used batteries. Unfortunately, the industry has not placed a high priority on this matter, even though the demand for it is rapidly approaching. Stena Recycling recognized this need and took the initiative to establish a battery recycling project in Halmstad. As the electric car market is growing rapidly, the need for additional battery recycling centers in various locations will become necessary.

AFRY’s role in the project

AFRY have contributed to the forming of Phase 1 in the battery recycling process. The challenge is to be able to handle a throughput of two tons per hour from any car manufacturer, with health and safety as the highest priority. Engineers from AFRY have designed the lifting table, transport wagon and the de-charging stations during the project.

The recycling plant's establishment is a significant step towards addressing the demand for a sustainable and environmentally friendly recycling process for used batteries, which is crucial for the growing use of electric cars. We are proud to be part of an initiative that helps expedite the transition to a more sustainable future,

says Jörgen Simonsson, Business Unit Manager, Connected Products at AFRY.

The result:

The project has created a complete system set-up to recycle electrical lithium-ion car batteries. The picture shows the lifting table, transport wagon and de-charging chambers (also called “U-boats” since they will be filled with water and lead away any dangerous gas in case of fire).

The Grand Opening Ceremony for the recycling plant was held on March 29th 2023, in Halmstad, Sweden, and Stena intends to spread this solution to other sites domestically and internationally. It's highly probable that AFRY will continue to aid in implementing the solution throughout Stena.