Willstätt GigaFactory 2 GWh

ongoing

The WGF2G project will establish a 2 GWh capacity Nickel Manganese Cobalt (NMC) Li-ion battery cell gigafactory to produce batteries for long-range transport applications. The project will manufacture batteries using a PFAS (Per- and Polyfluoroalkyl Substances)-free production process. It is a first-of-kind commercial upscaling of Leclanché’s PFAS-free cell manufacturing process in a scalable, high-efficiency production environment in Willstätt, Germany. During its first 10 years of operation, the project will avoid approximately 2.3 million tonnes of CO2 equivalent in GHG emissions. This equates to about 0.5 million passenger vehicles’ annual GHG emissions (source: Greenhouse Gas Emissions from a Typical Passenger Vehicle | US EPA). The project will use innovative PFAS-free and water-based cell manufacturing technology, eliminating harmful substances like PFAS and NMP (N-methyl-2-pyrrolidone). The water-based electrode production process is more energy-efficient than traditional methods requiring higher drying temperatures as organic solvents like NMP have higher boiling points than water. The drying temperatures for a NMP-based electrode manufacturing process can reach 150°C but remain below 100°C for a water-based process. The WGF2G gigafactory’s flexible design will support multiple cathode chemistries (e.g. high nickel content NMC, cobalt-free or LFP), allowing it to respond to market shifts, integrate recycled materials, and evolve toward full circularity. By doing so, the project positions itself as a blueprint for sustainable battery manufacturing in Europe and a key contributor to its green industrial future. The PFAS-free cell technology was chosen over alternative cell technologies for its environmental benefits and alignment with the European Green Deal and the EU Battery Regulation objectives, which aim to reduce reliance on hazardous substances. The WGF2G project complies with upcoming EU restrictions on the use of PFAS materials such as PVDF (polyvinylidene fluoride). The water-based binder electrode technology will also allow the elimination of NMP, which under the EU REACH Regulation is classified as a Substance of Very High Concern (SVHC) due to its reproductive toxicity. WGF2G will drive regional growth and job creation in the EU by building a skilled workforce, creating up to 250 direct and indirect jobs, collaborating with local suppliers, and fostering knowledge-sharing via European partnerships. The cell production plant will enhance European battery technology, aiding the shift to electric vehicles and green industry, reinforcing Europe’s global market position. WGF2G aligns with the EU’s decarbonisation and chemical strategy for sustainability. Backed by the Innovation Fund, the project’s scalability offers opportunities for further expansion in the EU and globally, promoting a sustainable, self-sufficient energy future in Europe.