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CIRCULAR BATTERY RECYCLING: A FUTUREPROOF ALTERNATIVE
Tom Machiels and Kobe Smeers, who graduated as engineers from the Diepenbeek campus in 2023, worked on a challenging and groundbreaking project for their master’s thesis: the development of a production line for the recycling of Li-ion batteries. The goal was to give discarded bicycle batteries a second life in the form of rechargeable block batteries, a sustainable alternative to the disposable batteries commonly used in road signage. This innovative project not only earned them their degree but also a participation in the Future Proof Award, a competition by the Flemish Government that rewards theses contributing to a sustainable future.
The world is facing an increasing problem of electronic waste production. Disposable batteries, such as those used in construction site signal lights, contribute significantly to this issue. “On every construction site, you see dozens of signal lights”, says Tom. “The batteries are often replaced before they’re even fully drained, simply because there’s no room for risk if the lights go out.” This leads to enormous amounts of waste.
The innovative solution from start-up Reacct offers a response to this problem. By recycling old bicycle batteries into rechargeable block batteries, they’ve developed a way to drastically reduce waste. “A rechargeable block battery not only lasts twice as long as a traditional dis- posable battery, but it can also be recharged multiple times, extending its lifespan up to five years”, explains Kobe. “This means that one of our block batteries can replace the work of as many as 40 disposable batteries.”
Challenges and Innovations
Kobe and Tom’s role involved developing a production line for these batteries, which presented several challenges. The production had to occur at a social enterprise that employs individuals with limited access to the job market. This required a linear and straightforward process that could be executed safely, simply, and efficiently. “The combination of automation and manual labor was crucial”, says Tom. “We adhered to the Poka Yoke principle, which virtually eliminates errors in the process. Each step was visually supported, ensuring that even individuals with less technical background could carry out the tasks.”
The software for the production line, including the control of an automated spot-welding process, was developed by the two master’s students themselves using LabVIEW. “Automating the welding process was a significant advancement”, adds Kobe. “It enabled us to ensure the quality and consistency of the block batteries while prioritizing safety.”
In addition to the welding process, they also created methods for adding rivets and electrical safety components and optimized the existing testing software. This blend of technical innovation and social engagement made their project unique within the field of engineering technology.
Social and Environmental Impact
In addition to the clear environmental benefits, collaborating with a social enterprise added a valuable social dimension to the project. “We didn’t just want to develop a sustainable battery; we also aimed to create job opportunities for individuals facing barriers to employment”, says Tom. “By designing a simple, visually supported production process, these employees can easily take on crucial roles in assembling the batteries.”
From an ecological perspective, the REBLOCC block battery exemplifies how recycling and material reuse can contribute to a circular economy. “A rechargeable block battery replaces at least 16.2 kilograms of disposable batteries”, explains Kobe. “This leads to a 98% reduction in waste, which is a significant advancement in the fight against a throwaway society.”
The financial benefits are equally compelling: the higher initial cost of rechargeable batteries is recouped in under two years, resulting in a 66% cost savings over the battery’s entire lifespan.
Future Perspective
By participating in the Future Proof Award, Tom and Kobe have shown that their work extends beyond the confines of academia. “We hope our project can serve as an in- spiration for other companies”, says Tom. “By investing in sustainable solutions, we can effectively tackle the environmental challenges we face today. ”Kobe concludes, “The world is moving towards a circular economy. We have demonstrated that engineers play a crucial role in this transition.”
Veerle Moons
