SUSTAIN-SEP – Sustainable Separator Scale-Up for Safer Batteries

Purpose and goal

The project will scale up sustainable battery separators, with Senior Materials Europe AB as coordinator with support from RISE AB and Celanese AB. The project will develop advanced separators made from sustainable materials, with nanocellulose and polymer ceramic coatings with reduced PFAS content. The solutions will improve safety, wetting and thermal stability. The project will scale up from the current TRL 5 level to TRL 7-8 by demonstrating separators in a relevant environment.

Expected effects and result

Upscale sustainable separator technology from TRL 5 to TRL 7–8, by integrating European-sourced bio-based UHMWPE, nanocellulose, and sustainable binders into industrially coated separators. The aim is to create a PFAS-reduced, environmentally friendly separator solution fully aligned with European sustainability requirements. Enhanced competitiveness for the Swedish and European battery ecosystem, with new value chains for sustainable separators and improved readiness for production.

Planned approach and implementation

Senior Materials is leading the industrial implementation, where Celanese supplies bio-based UHMWPE. RISE supports the procurement and characterization of nanocellulose and sustainable binders, as well as validation in relevant environments and LCA/TEA frameworks. These materials will be scaled up to continuously coated separator rolls and validated in cells. The scale-up will be made in a modern production facility in Eskilstuna, using advanced sustainable raw materials from Sweden/Europe.