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Executive Summary In January 2019, API commissioned Kelleher Environmental(Kelleher) to conduct a study involving an extensive trade journal and literature search as well as interviews with industry representatives to identify the current and near-term future processes employed for the reuse and recycling of EV batteries, and to identify existing available information on the technical, environmental, energy and cost issues associated with EV battery reuse and recycling. The study identified that almost 690,000 electric vehicles (EVs) including hybrid electric vehicles (HEVs), plug in hybrid electric vehicles (PHEVs) and battery electric vehicles (BEVs) were sold in the US in 2018. EV sales are projected to grow to an estimated market penetration rate of 8% by 2025, resulting in sales of 1.3 million PHEVs and BEVs in that year in the US The adoption of EVs is moving rapidly in the US and across the globe as EV battery technology improves and the costs of the batteries, and therefore the costs of EVs decrease. It is projected that when the costs of EV batteries reach a range of $80/kWh to $100/kWh the costs of EVs will reach parity with similar ICE models. EV battery costs are projected to reach $100/kWh anywhere from 2020 to 2025. This may lead to increased EV sales and eventually more EV batteries requiring end of life (EOL) management. Based on historical EV sales from 2000 to 2018, and current EV sales projections to 2023, it is estimated that about 525,000 EV batteries will reach EOL in 2025 with over 1 million units projected to be at EOL by 2030. While most of the batteries in the EOL EVs will be nickel metal hydride (NiMH) batteries from HEVs for the next few years, by 2025 most EOL EV batteries will be li-ion based. Recycling options are different for these two battery chemistries, with NiMH batteries directed to nickel operations whereas li-ion batteries are of more interest to cobalt recovery companies. There is no established collection infrastructure for EV batteries in the US at this time, as the numbers are low and they are scattered in small numbers at vehicle dealerships, repair shops and scrap metal shredding facilities located throughout the country. EV batteries are beginning to show up at scrap yards in sufficient numbers to raise concerns about proper management through either reuse or recycling. EV battery reuse appears to be a viable business model with good profit margins if issues around liability and standards can be addressed. It is considered more likely that EV batteries will be directed to reuse (energy storage systems, back-up power, EVs and various other applications such as wheelchairs and drones, etc.) for the foreseeable future because of the favourable economics. The study research did not find any evidence that EV battery recycling will be carried out at a positive value in the next five years, as the technologies that promise to achieve high recovery rates for the metals contained in EV battery cathodes have not yet been proven at commercial scale to date, and reuse is already proven to result in a positive cash flow. However, the business case for EV battery recycling needs to be developed in more detail than is currently available to better understand the economics of this approach. Traditional li-ion battery recycling focuses on recovering the cathode metals (nickel and cobalt in KELLEHER RESEARCH STUDY ON REUSE AND RECYCLING OF BATTERIES EMPLOYED IN ELECTRIC VEHICLES FINAL REPORT SEPTEMBER, 2019 PAGE 1PDF Image | Reuse and Recycling of Batteries Employed in Electric Vehicles
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