VALENCIA, Spain – Aeroborn will unveil its breakthrough technology for extracting graphite and producing graphene from black mass at the European Battery Recycling Association (EBRA) conference in Valencia on September 9, 2025. The innovative process not only recovers battery-grade graphite but also creates graphene-hybrid anode materials offering over three times the capacity of traditional graphite.

Game-Changing Technology for Critical Raw Materials

While most black mass recyclers focus on recovering metals like lithium, cobalt, and nickel, Aeroborn has developed proprietary technology to extract and upgrade the carbon content – specifically graphite – that typically comprises 25-40% of black mass. This overlooked resource becomes the foundation for next-generation battery materials.

The dual-output process delivers:

• Battery-grade graphite: Recovered and purified for direct reuse in new battery production

• Graphene-hybrid anodes: Advanced materials with 3x the capacity of conventional graphite anodes

This approach transforms what was previously considered waste carbon into Europe's most valuable battery materials, addressing critical supply chain vulnerabilities while advancing battery performance.

Strategic Importance for Europe's Battery Independence

Graphite represents the largest component by weight in lithium-ion batteries, yet Europe remains almost entirely dependent on imports, primarily from China. The EU has classified both natural and synthetic graphite as critical raw materials, recognizing their essential role in the battery value chain.

Aeroborn's technology offers multiple strategic advantages:

• Domestic graphite supply: Reducing Europe's 90%+ import dependency

• Superior performance: Graphene-enhanced anodes exceeding current technology

• Circular economy leadership: Complete utilization of black mass components

• Value creation: Transforming waste into high-margin advanced materials

Revolutionary Graphene-Hybrid Anode Technology

The breakthrough lies in Aeroborn's ability to convert recovered graphite into graphene and integrate it into hybrid anode materials. With over 3x the capacity of traditional graphite anodes, these materials could revolutionize battery performance:

Technical advantages:

• Significantly higher energy density

• Faster charging capabilities

• Extended battery lifecycle

• Improved thermal stability

Market implications:

• Enabling longer-range electric vehicles

• Reducing battery size and weight

• Supporting next-generation energy storage

• Creating competitive advantage for European battery manufacturers

Addressing the Complete Black Mass Value Chain

Unlike conventional approaches that leave carbon as waste residue, Aeroborn's process maximizes value extraction from every component:

1. Carbon separation: Advanced techniques isolate graphite from metal-rich fractions

2. Purification: Achieving battery-grade specifications for recovered graphite

3. Graphene production: Converting graphite into high-quality graphene

4. Material engineering: Creating optimized graphene-graphite hybrid structures

This comprehensive approach aligns with EU circular economy principles while creating materials that surpass virgin alternatives.

Market Transformation Potential

Aeroborn's technology addresses multiple market needs simultaneously:

For recyclers:

• Additional revenue streams from carbon fraction

• Complete black mass valorization

• Differentiation in competitive markets

• Meeting stricter recycling efficiency targets

For battery manufacturers:

• Secure domestic material supply

• Next-generation anode materials

• Reduced carbon footprint

• Performance advantages over competitors

For Europe:

• Reduced critical material dependencies

• Technology leadership in advanced materials

• Circular economy exemplar

• Strategic autonomy in battery value chain

Regulatory Alignment and Environmental Impact

The technology directly supports EU objectives:

• Critical Raw Materials Act targets for domestic production

• Battery Regulation requirements for recycled content

• Circular economy goals for waste minimization

• Carbon neutrality ambitions through material efficiency

By recovering and upgrading carbon materials, the process significantly reduces the environmental impact compared to virgin graphite production, which is energy-intensive and environmentally challenging.

Future Outlook

As the battery industry seeks performance breakthroughs while addressing sustainability challenges, technologies that deliver both become increasingly valuable. Aeroborn's graphite recovery and graphene production process represents a paradigm shift in black mass recycling – from waste management to advanced materials manufacturing.

The Valencia conference offers EBRA members an exclusive opportunity to explore how this technology can transform their operations and position them at the forefront of the battery materials revolution.

For more information about EBRA: www.ebra-recycling.org