Garages concerned about the growing quantities of end-of-life lithium-ion EV batteries now have a solution. Recyclus Group, a British company, has launched its first industrial-scale lithium-ion battery recycling plant in Wolverhampton, with plans to open five more plants within the next five years. This development comes at a time when there is increasing concern about the environmental impact of extracting and refining raw materials for lithium-ion batteries, as well as the millions of tonnes of waste that will accumulate worldwide by 2030.

Recyclus Group aims to address these concerns by extracting valuable raw materials from discarded batteries and supplying them to battery manufacturers, including car makers. The company plans to recycle up to 8300 tonnes of batteries each year, yielding enough lithium to power 7500 new EV battery packs. By 2040, Recyclus believes that the motor industry could source 20% of its lithium from recycling.

The recycling process involves extracting valuable materials such as nickel, manganese, lithium, and cobalt from the batteries. These materials are present in five different chemistries and are extracted in the form of a toxic powder called “black mass.” Recyclus plans to offer a process to separate and purify these materials for recycling in the future.

Used batteries are collected by logistics partner Slicker and transported to Recyclus in specially designed steel containers called LiBox containers. These containers are highly secure and packed with battery “pillows” containing non-combustible filler to prevent fires caused by thermal runaway. The batteries are then crushed and shredded by a 10-ton rotor, with nitrogen gas pumped into the shredding area to prevent fires. The electrolyte is recovered, and the black mass is extracted. The remaining parts of the battery go through further processes to separate polymers and ferrous and non-ferrous materials. The entire process is dry, eliminating the need for water.

While the system is still being tested, it is expected to produce enough black mass to fill a large industrial drum every hour. Currently, the material fetches £5000-£6000 per kilogram on the open market. However, the economics of recycling the four constituent parts of the black mass are finely balanced. Nickel and cobalt are cheaper to recycle compared to sourcing them from raw materials, while manganese is comparable in cost. On the other hand, recycling lithium is more expensive.

Recyclus plans to sell its recycling system to operators, including gigafactories and car makers. The company is also exploring the possibility of offering a mobile, truck-mounted service in collaboration with the University of Birmingham. This service would process end-of-life batteries on-site, providing a convenient solution for car makers and other industries.

Another British start-up, Altilium Metals, is working on separating black mass and purifying the four metals it contains: lithium, nickel, manganese, and cobalt. The company aims to upscale these metals’ chemistries to create modern batteries with higher performance and longer range. Altilium Metals has received a £5 million grant from the UK government and plans to have a factory in Teeside shredding batteries and providing 30,000 tonnes of refined and upscaled cathode-active material each year by 2026. However, this will only meet 30% of the predicted demand from the UK motor industry.

The development of industrial-scale lithium-ion battery recycling plants like Recyclus and Altilium Metals is crucial for addressing the growing waste battery problem and reducing the carbon footprint of industries. With millions of tonnes of waste batteries expected to accumulate worldwide in the coming years, it is essential to find sustainable solutions that allow for the extraction and reuse of valuable materials. These recycling plants not only provide a way to dispose of batteries responsibly but also offer an opportunity to secure a sustainable supply of raw materials for battery manufacturers, supporting the transition to a circular, low-carbon economy.