Can EV batteries be recycled?

Yes, EV batteries can be recycled.

The recycling of EV batteries is of paramount importance because these batteries have not only heavy metals but toxic chemicals which are very harmful to the ecosystem and mankind.

The EV batteries which are also called lithium-ion batteries are composed of cathode, anode, electrolyte, separator along with some other materials.

As you know, lithium-ion batteries contain heavy metal and toxic chemicals so recycling EV batteries in an environmentally friendly manner is mandatory.

But going forward how EV batteries are recycled, first understand the EV batteries components so that it becomes easy why recycling of EV batteries is required.

 

At the end of this article, you would be able to understand the EV batteries components & their importance, the next generation EV batteries roadmap which can drive EVs more than 310 miles, enhanced safety features of EV batteries, and the EV batteries recycling process.

So, let’s start.

The EV batteries are made of four components

1. Cathode
2. Separator
3. Electrolytes
4. Anode

The cathode has the Cathode Active Material (CAM), which costs 40% of EV battery production cost. This is a major contributor to how much your EV’s battery would last.

There is research also going on ‘single crystal cathode material’ which will reduce the gas emission by 85%.

The cathode active material (CAM) consists of four major components which are called NCMA namely

1. Nickel
2. Cobalt
3. Manganese
4. Aluminium

These are four core materials which determine the key performance of EV batteries such as capacity and life.

The raw material for cathode manufacturing in EV batteries contains Nickel, Cobalt, Manganese, and Aluminium, accounting for approximately 70% cost of cathode manufacturing.

This raw material of EV batteries is called the precursor.

The NCMA material of cathode provides outstanding stability and output to EV batteries.

The role of Nickel in EV batteries:

To make the best battery for EV cars there is a high quantity of Nickel required in cathode active material.

So, EV batteries making companies are planning to increase their content by more than 80%.

Even a few EV batteries making companies have more challenging goals to have more than 90% Nickel in Cathode so that they can make such EV batteries which can drive EVs more than 310 miles at an affordable price.

But there is one problem with Nickel also that only one-fifth of Nickel in the world is suitable for making EV batteries.

The role of Cobalt in EV batteries.

The second element of cathode active material is cobalt.

The purpose of Cobalt in making cathode active material is, it allows a high rate of lithium-ion delivery to the anode and oxidises easily to make a stable lithium cobalt oxide compound.

This lithium cobalt oxide compound prevents excess oxygen molecules from producing a fire hazard.

But there is one problem with Cobalt also it is toxic and expensive and mining of this metal is being carried out by bypassing the laws.

The mining of Cobalt impacts the environmental footprints and may outweigh the reduced environmental carbon footprints of EV batteries.

So, for making the next generation EV batteries, the major focus is on Cobalt free EV batteries for large scale

For making the Cobalt-free EV batteries, the Manganese is the front runner which has huge potential to replace the Cobalt.

The role of Manganese in EV batteries.

The alternative of Cobalt-free EV batteries is seen in Manganese as Manganese provides better safety than Cobalt.

Secondly, Manganese is much cheaper than Cobalt.

Whereas Cobalt trading in the US market at $50000 per metric ton approximately, Manganese trades at $1500 per metric ton.

So, with this change, the EV-making companies would have a better profit margin and allocate funds to research & development for making safer lithium-ion batteries.

Thirdly, as compared to Cobalt it’s easily available in the supply chain, so planning of producing more batteries could be done in a better way.

So, investing in such EV batteries stock metals also could be a good decision in the coming years.

The role of Aluminium in EV batteries

By applying aluminium, it reinforces the stability by expanding nickel content, which determines the energy density, to around 90%.

The energy density is the primary factor in EVs that how much a battery would cover a distance one charge.

Aluminium provides more stability as compared to Lithium as it can exchange three electrons for every ion whereas Lithium exchanges one electron for every ion.

And with this feature of Aluminium, it enables up to three times more energy density of EV batteries.

Secondly, Aluminium-based EV batteries can be recycled easily as compared to Lithium-based EV batteries.

In the coming year for next-generation batteries, the Aluminium ion battery would replace the Lithium-ion battery due to its high energy density feature and would be available at affordable prices.

The role of separator in EV batteries

The separator is a thin porous membrane that physically separates the anode and cathode.

The basic purpose of the separator is to prevent the physical contact of anode & cathode while allowing the ion to transport in the cell.

The real challenge to making a good quality separator is to compromise either on porosity or robustness.

A good quality separator is one which has both.

As the power requirement from Lithium-Ion batteries increases, safety and reliability is also paramount requirement.

A ceramic technology-based separator would be used for next-generation EV batteries because ceramic provides excellent quality against high temperatures.

Hence it makes EV batteries safer than earlier.

The role of electrolytes in EV batteries

The electrolytes are the third important but unappreciated component of EV batteries.

The role of electrolytes is to enable the smooth movement of lithium ions between the cathode and anode.

The two types of electrolytes used in EV batteries are aqueous and non-aqueous.

The research is going on to make better electrolytes. The non-aqueous solid type of electrolyte is a better option with enhanced safety and affordable cost material.

The role of Anode in EV batteries

Just like the cathode, the anode is also fourth an important part of lithium-ion batteries.

An anode is a negatively charged electrode that discharges lithium ions into electrolytes.

In the process of charging an electric vehicle, the lithium-ion flows towards the cathode while in the charging process the lithium ions flow from cathode to anode.

The existing anode used in lithium-ion batteries is graphite powder.

But for making next-generation EV batteries, the pure silicon-made anode can play a pivotal role.

Because it is available in abundance on earth’s crust and at an affordable cost.

R & D is going to make its practical use because It is much safer than graphite due to its low working potential.

The other EV battery components are also used which include the cathode nanotubes (CNT), thermal adhesives, anode binders, and battery assembly solutions.

EV Batteries Recycling Process

Now we know all the components of EV batteries and their importance.

As you know EV batteries contain Nickel, Cobalt, Manganese, Aluminium, and some other chemicals which have economic value also.

If these metals are extracted from spent EV batteries, then it can be used in making new batteries and will save a lot of natural resources.

The recycling of EV batteries includes two types of processes. The first process is called the Dry Process, and the second one is called the Wet process.

Each process has its own pros & cons. Some new technologies are using both processes.

Dry Process of EV batteries recycling

The first process, the dry process also called the Pyrometallurgical process includes roasting, smelting, and converting.

This process is good for extracting Nickel, Cobalt, and Manganese but not so good for extracting Aluminium and Lithium.

Along with this, the process is capital & power intensive.

Wet Process of EV batteries recycling

The second process which is used for EV batteries recycling is called the hydrometallurgical process is known as the wet process.

This process recovers aluminium and lithium along with other metals, but this process is long which is its major disadvantage.

This process includes the pre-treatment, leaching, solvent extraction and precipitation.

The good thing about this process is its less capital & power-intensive process.

Conclusion

Electric vehicles are new transportation for the next generation as fossil fuels are going down very rapidly.

Providing EVs at an affordable price is another challenge along with EV batteries recycling

So, to make a sustainable ecosystem for transportation, electric vehicles can play a pivotal role.

But with the increase of EVs, the consumption of EV batteries will also increase and hence the number of spent EVs batteries will also increase.

So, EV battery recycling should happen in a sound environment-friendly way as it has both heavy metals and toxic chemicals which are very harmful to the environment & human health.

The recycling of EV batteries would be a big challenge to take EVs to the next level.

What do you think about it?