Electric vehicle (EV) batteries are not easy to recycle. However, scientists and companies are finding new ways to extract rare materials from used batteries. These materials can then be reused to make new batteries.
Inside a lab where old batteries are destroyed and reborn
At a special lab in Southwest England, workers break down large batteries. This process creates a black powder known as “black mass.” It contains valuable elements like lithium, nickel, cobalt, and graphite, which are separated and reused.
Why the demand for battery materials is growing fast
As more people buy electric vehicles, battery demand is rising. According to the International Energy Agency (IEA), one out of every five cars sold in 2023 was electric—a 35% increase from 2022. This growing demand has pushed the prices of essential battery materials higher.
These materials come from risky places
Half of the world’s nickel comes from Indonesia, while two-thirds of the cobalt comes from the Democratic Republic of Congo—both places with human rights concerns. This has led to a global race to find safer, more sustainable sources like battery recycling.
A recycling company that started from a small shed
A company named Altilium began in late 2020 but faced delays due to the COVID-19 pandemic. In mid-2022, the founders started operations in a small rented space. Within three years, they built a full-scale factory supplying recycled materials to battery makers.
Few companies are working on battery recycling
Only a few firms globally are developing technology to recycle EV batteries. These companies claim they are helping reduce carbon emissions. As EVs become more popular, many batteries are reaching the end of their life, making recycling even more important.
Recycling helps reduce toxic waste
Reusing batteries stops dangerous materials from entering the environment. In the U.S., government policies under President Joe Biden supported companies like Li-Cycle and Redwood Materials, which now have plants in Canada, the U.S., and Germany.
Tesla co-founder is also in the game
Redwood Materials, founded by a Tesla co-founder in 2017, works with major car companies like Toyota, Volkswagen, and BMW to recycle batteries. Many new and old companies are now investing in this field.
Challenges still remain in battery recycling
Battery recycling is still in its early industrial stage. For example, German chemical company BASF paused its battery recycling project in Spain, although it still plans to continue in the future.
Why battery structures are hard to break down
EV batteries are made of two thin layers: the anode and cathode. Anodes, often made of graphite, release electrons, while cathodes store them and contain metals like lithium, nickel, and cobalt. These layers are tightly packed, making them hard to separate and reuse.
Toxic and dangerous materials inside batteries
Many valuable elements in EV batteries are toxic or flammable. These risks make recycling even harder, but still necessary to protect both people and nature.
Altilium’s unique way to extract useful materials
Altilium crushes batteries and uses hot water instead of burning to reduce emissions. They soak the black mass in sulfuric acid, helping to extract graphite and other elements. The remaining solution contains cheaper metals like copper, iron, and aluminum, which are also filtered and reused.
Turning leftover acid into useful products
Even the used acid is recycled. It’s processed into grey powder, which is later used in building materials. This minimizes waste and supports sustainability.
Extracting high-value metals like nickel and cobalt
The Altilium team is now able to isolate high-value metals like nickel, cobalt, and manganese. These are separated using different chemical solutions. As EV battery chemistry keeps changing, this process remains complex and challenging.
Why nickel is important for future batteries
Battery makers prefer nickel because it stores more energy in less space. However, it’s expensive, so companies are exploring alternatives. Reusing nickel and other minerals helps reduce the need for new mining, saving both money and the environment.
Recycling supports the circular economy
Recycling old EV batteries reduces carbon emissions and avoids digging new mines. This supports a circular economy where materials are reused again and again, as explained by Altilium co-founder Christian Marston.
Future batteries might be made from recycled materials
Researchers believe that by 2040, half of the lithium and nickel needed for new batteries could come from recycled ones. In the next 5 to 10 years, battery recycling is expected to become more common.
Governments are pushing battery recycling
The European Union (EU) introduced new battery rules in 2023. From 2025, all new batteries must be easier to recycle and must allow the recovery of useful materials. These laws are designed to protect the environment and support green energy goals.
Geopolitical benefits of recycling
Battery recycling isn’t just good for nature—it also helps countries reduce their dependence on foreign suppliers. With rare minerals often coming from politically unstable areas, having local recycling options adds economic and strategic security.
