Sustainable Scale‑Up of Dichloromethane‑Free Battery Separators Manufacturing in Sweden (DCM-Free-SE)

Purpose and goal

This project will establish the world’s first production-scale dichloromethane (DCM)-free wet-process separator manufacturing technology in Sweden. By introducing an innovative production process, it will significantly reduce the environmental impact and improve the sustainability of Senior Material’s manufacturing operations in Eskilstuna. The project will also position Sweden as a global leader in sustainable high-voltage battery separator production in close collaboration with KTH and RISE.

Expected effects and result

Industrialization of DCM-Free Wet-Process Separator (TRL 7–8): Validated at industrial scale in Eskilstuna, this breakthrough delivers a zero-DCM manufacturing route that eliminates restricted extraction chemical use while creating a safer working environment. By enhancing physical properties and electrochemical performance, this regulatory-ready and sustainable process secures a high-performance, green foundation for the European battery value chain’s strategic autonomy.

Planned approach and implementation

The project will scale the technology from TRL 5 to TRL 7–8 through integration of upgrading the extraction unit, and industrial-scale validation. • WP1 manages coordination; • WP2 focuses on localized system design; • WP3 implements equipment upgrades; • WP4 validates continuous production performance; • WP5 conducts LCA, TEA, and regulatory compliance assessments. Progress is monitored through milestone-based reviews supported by an advisory board and external engineering expertise.