The Centre for Solar Energy and Hydrogen Research Baden-Württemberg (ZSW) has launched the “Powder-Up!” pilot plant in Ulm, marking a significant milestone in Germany’s battery manufacturing capabilities. The facility enables the independent production of battery materials and their precursors, a first of its kind in the country.
The inauguration of the plant represents a breakthrough in Germany’s ability to produce battery materials outside of industry, with a capacity of up to 100 kilograms. The ZSW aims to offer this manufacturer-independent development platform to partners from industry and science, utilizing industry-proven machines to ensure near-series production conditions. The focus will be on innovative cathode materials crucial for high-energy batteries.
With a usable area of 2,400 square meters, the pilot plant covers all production steps necessary for manufacturing high-energy battery materials. This includes a precipitation plant for precursors, high-temperature heat treatment, and various post-processing options, as well as new chemical laboratories and high-precision analytical measuring equipment. The plant is designed to quickly produce and test different product samples, reducing development cycles.
According to the ZSW, the ability to test new materials in small battery prototypes was limited in Germany until now, with larger quantities typically supplied by large industrial manufacturers, often located outside of Europe. However, the materials produced in “Powder-Up!” will be sent to pilot plants at research institutes or battery manufacturers, enabling the construction of full-size batteries.
The construction of the pilot plant was funded by 24 million euros from the Federal Ministry of Education and Research (BMBF), with an additional 10 million euros from the Baden-Württemberg State Ministry of Economic Affairs, Labour, and Tourism. The inauguration was attended by German Federal Research Minister Bettina Stark-Watzinger, who hailed the facility as a crucial component in developing a competitive and sustainable battery value chain in Germany and Europe.
Prof. Dr. Markus Hölzle, Head of ZSW in Ulm, highlighted the significance of the pilot plant, stating, “With the Powder-Up! pilot plant, such cathode materials can now be produced for the first time outside of industry in a near-series environment.”
The ZSW in Ulm is already equipped with a large pilot line for industrial production of lithium-ion cells up to 80 ampere-hours since 2014, and a battery safety and test center since 1998. The center’s research also focuses on recycling processes for production waste and metals from used lithium-ion batteries, as well as designing innovative battery cells without critical and environmentally harmful materials.
