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particular) in metal form. Decisions on recovering other materials depend on metal content of various side streams from the process (e.g. fluff with 65% steel) and available markets. Various slags produced from the recycling operation are either used for construction or landfilled. Plastics are either burned or landfilled but are not recycled and the graphite is not recycled at this time. The metals recovered from the processes are sent to smelters for further recovery through pyrometallurgical (heat based) processes. The recovery rate through the smelting process is generally around an average of 50% measured by weight, but can range from 40% to 80% depending on metal content and markets. A number of new EV battery recycling technologies c u r r e n t l y in development attempt to increase the recovery rate for various metals such as cobalt and nickel through the recycling system. These technologies focus on hydrometallurgical processes, which are less energy intensive than pyrometallurgical processes. The new EV battery recycling technologies commit to increasing recycling rates to a reported 90%+. Results to date are from small scale operations recycling pure production scrap or small batches of EV batteries as a feed stream. It is considered unlikely that metal recovery rates of 99% or 100% are sustainable when mixed loads of EV batteries are processed. The companies developing these new EV battery recycling technologies are most interested in direct recycling or cathode-to-cathode recycling to recover chemicals and chemical powders suitable for direct sale back to battery manufacturers. Some of these companies only process battery cathodes, leaving the discharging and dismantling of the EV battery to a separate company. None of these technologies are yet operating at scale. The environmental benefits of EV battery reuse relate to extending the lifespan of the battery and reducing the demand for virgin materials to manufacture new EV batteries. EV battery recycling secures supplies of metal such as cobalt which is essential for EV battery production using current technologies, but which is sourced from unstable countries such as the Democratic Republic of Congo which has most of the global reserves of cobalt. While a number of studies were found identifying environmental and energy impacts of reuse and recycling of EV batteries, none reflected current conditions and current battery chemistries. Future research should focus on updating these studies to reflect current conditions in the US, for both EV battery reuse and recycling. Both reuse and recycling of EV batteries share the technical challenge associated with the availability of a wide range of battery formats, designs, compositions and chemistries, and a lack of design for easy dismantling and recycling. This makes standard approaches virtually impossible at this time, and requires customized approaches. Both reuse and recycling also suffer from a lack of collection infrastructure to bring accumulated EV batteries to a central location where large numbers would lead to economies of scale. Compared to the US, other countries spend considerably more on supporting research into new EV battery technologies and recycling, as they see battery development as a potential large business in the future and want to be leaders in technology development and deployment. Examples include the UK Faraday Fund which has dedicated $51 million to li-ion battery recycling research and $113 billion committed by the European Battery Alliance which includes governments and private sector partners to build battery giga-factories and research battery recycling. The opinions in this report are based on best available information available as of mid-2019. The EV field is evolving rapidly therefore this report needs to be updated in mid-2020 to remain current. KELLEHER RESEARCH STUDY ON REUSE AND RECYCLING OF BATTERIES EMPLOYED IN ELECTRIC VEHICLES FINAL REPORT SEPTEMBER, 2019 PAGE 2PDF Image | Reuse and Recycling of Batteries Employed in Electric Vehicles
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