As electric vehicle (EV) sales soar, so does the demand for the rare metals required to power their batteries. With an increasing number of EVs reaching the end of their life cycles, the challenge of recycling these batteries has become more critical than ever. Companies like Altilium, a recycling firm in the UK, are leading the charge in developing innovative techniques to reclaim valuable materials from used batteries, offering a potential solution to the growing shortage of materials like lithium, nickel, and cobalt.
At Altilium’s lab in Tavistock, south-west England, a process is underway to recycle the crucial minerals from batteries that would otherwise be discarded. What arrives at the lab is a substance known as “black mass,” a dark powder made from pulverized batteries. This powder contains a mix of materials, including plastic, steel, and valuable metals, which Altilium staff extract through a combination of advanced techniques.
Christian Marston, President of Altilium, explained the urgency of this work, noting that the global demand for minerals such as nickel and cobalt, primarily sourced from regions like Indonesia and the Democratic Republic of Congo, raises significant ethical concerns due to ongoing human rights issues linked to mining. “One of the big challenges is that these minerals are concentrated in certain places,” Marston said.
As global efforts intensify to combat climate change, the need for EVs and renewable energy technologies is expected to keep growing. The International Energy Agency (IEA) reported that nearly one in five cars sold in 2023 was electric, marking a 35% increase from the previous year. This surge in demand has led to a sharp rise in the need for raw materials for EV batteries, creating an urgent need for sustainable recycling practices.
Altilium’s process begins with shredding old batteries into black mass. The lab then uses hydrometallurgy, a water-based method, to extract materials like lithium, nickel, cobalt, and graphite, which are essential for new batteries. Unlike traditional pyrometallurgy, which involves high temperatures and creates significant emissions, hydrometallurgy is more environmentally friendly. This approach not only reduces emissions but also allows Altilium to recover valuable materials that can be sold to battery manufacturers.
Despite these advancements, battery recycling remains a complex challenge. Each EV battery contains multiple layers of materials, including metals like lithium and cobalt, which are often tightly integrated, making extraction difficult. Altilium’s solvent extraction techniques allow for the separation of individual metals, a critical step in supplying manufacturers with the specific mixtures needed for new batteries.
While Altilium is one of the few companies specializing in EV battery recycling, there is growing interest worldwide. Firms such as Li-Cycle in the U.S. and Redwood Materials, founded by a Tesla co-founder, are also developing technologies to recover critical minerals from old batteries. According to experts, the recycling industry is still in its early stages, but the potential for significant growth is clear.
The benefits of battery recycling are not only environmental but also geopolitical. Reducing reliance on mining could help mitigate the risks posed by unstable supply chains, especially as countries face disruptions like Brexit and trade tensions. By 2040, researchers estimate that recycling could meet more than half of the demand for materials like lithium and nickel, easing the strain on natural resources.
As governments like the European Union introduce stricter regulations on recycling efficiency, the hope is that innovations in this field will help create a circular economy, where raw materials are continually reused, reducing the need for new mining and its associated environmental and human costs.
