EV battery life generally exceeds warranty periods. In moderate climates, batteries are expected to last between 12 and 15 years and in harsher ones, an eight to 12-year lifespan appears to be the norm. However, the question of what happens to EV batteries after that often arises.
Are EV Batteries Recyclable?
Recycling EV batteries certainly is possible, but it is labour intensive and it requires considerable skill to disassemble them.
In addition, recyclers themselves are faced with the question of just how much to recycle, and how cost-effective the most comprehensive forms of battery recycling may be. For example, while nickel and cobalt are valuable and will be well-worth recovering, additional materials like copper, aluminium and plastics may be less commercially viable.
As ever-growing numbers of batteries are recycled, it will be necessary to expand capacity and realise greater efficiency. This article provides an overview of current methods, promising new technologies, and the challenges to which the automotive industry must rise by 2030.
Electric Vehicle Battery Recycling Processes
Currently, there are two ways to recycle EV batteries. In a pyrometallurgical process, the batteries are broken up into small pieces and incinerated. The resulting “black mass” containing valuable minerals is then further processed to extract valuable elements. A hydrometallurgical process uses acid to dissolve materials into a liquid state. Thereafter, elements can be extracted. Both recycling methods must be closely controlled to limit risks to employees and prevent environmental harm.
Researchers are working on improving such processes. For example, switching to oxalic acid in a hydrometallurgical process allows for efficient recovery of lithium and aluminium and minimises loss of cobalt, manganese and nickel. Another possible approach would be to create a water-based solution containing oil. Under a specific set of conditions, molecules can be drawn out of the solution. The use of a solvent free flash Joule heating process appears to be particularly promising. A current is passed through battery waste, rapidly heating it to 2,500 degrees. Thereafter, a metal recovery yield of 98 percent is possible.
The labour-intensive process involved in EV battery disassembly is being tackled using assembly line robotics. However, there are challenges to overcome: in particular, a lack of standardisation. EV batteries from various producers differ in their chemistry, size, and form and safety is an important concern.
Reuse of EV Batteries
Most EV batteries can be repurposed. When an electric vehicle’s battery is replaced, it is far from exhausted. Often, used EV batteries retain 70 to 80 percent of their capacity. These batteries may not be suitable for EVs, but they can be used in Battery Energy Storage Systems.
For example, energy storage is one of the challenges faced in clean energy generation such as solar and wind power. Because sun and wind conditions vary, too much energy may be produced at times, while at others, too little is produced. Battery Energy Storage Systems can store surplus energy, making it available when energy generation conditions fail to meet demand.
Electric Vehicle Battery Recycling Market: 2030 and Beyond
As ever more electric vehicle batteries reach the end of their useful lives, efficient, safe recycling processes will become ever-more important. It’s estimated that by 2030, the UK alone will have 28,000 tonnes of batteries requiring recycling. By 2040, that volume will rise to 235,000 tonnes.
Vast amounts of valuable minerals will be awaiting recovery, and the batteries themselves will present an environmental risk if they are simply discarded. Recycling EV batteries is already a highly-specialised field with few companies having the necessary expertise to undertake the process safely.
To meet future demand, it will be necessary to build capacity and implement new technologies effectively. UK battery recycling companies are watching recent developments in EV battery recycling with interest.
There are already significant regulatory battery recycling and recycled content requirements coming from the EU, a road down which the UK is likely to follow shortly:
- By 2026 – Recycling target of 65% weight lithium-ion batteries, 75% lead-acid batteries
- By 2031 – Recycling target of 70% weight lithium-ion batteries, 80% lead-acid batteries
- By 2028 – Recovery target of 50% lithium, 90% cobalt, copper, nickel, lead By 2032 – Recovery target of 80% lithium, 95% cobalt, copper, nickel, lead
- By Aug 2031 – Minimum recycled content requirement for 16% cobalt, 85% lead, 6% lithium, 6% nickel from non-virgin sources
- By 2036 – Minimum recycled content requirement for 26% cobalt, 85% lead, 12% lithium, 15% nickel from non-virgin sources.
SMMT: Representing the Auto Industry From Manufacturing to Recycling
SMMT unifies industry voices, representing member interests at the highest levels of government. We encourage all companies with an interest in the UK’s transition to emission-free vehicles to become members. Along with advocacy, you will enjoy inside access to data and reports to guide your business strategies through the EV transition. Join us today as we work toward a better tomorrow.
