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Mechanical processes: Mechanical processes are used to safely remove the electrolyte and break the EV battery components apart to concentrate the metals and make them easier to process. Batteries may be fed via a conveyor into equipment like a shredder that can break the battery components into small pieces that are then directed to recycling. Hydrometallurgical processes: This refers to the aqueous processing of the metal-containing streams, in order to recover metals. The metals output from mechanical separation (which contain cathode metals) is further chemically processed to produce a solution, which undergoes electrolysis, or other treatment, in order to separate out the dissolved metals, which results in metal salts. Companies involved in hydrometallurgical processes keep their chemical and aqueous phase formulations and procedures quite proprietary. The metal salts are marketable commodities which are sent to smelters to recover materials such as nickel and cobalt. Pyrometallurgical processes: Pyrometallurgical processes use high temperatures to transform, separate and purify metals. Because achieving these high temperatures requires sophisticated, capital-intensive equipment with strict safety and environmental controls, pyrometallurgical extraction occurs at a smelter, not in smaller operations. There is no generic method for recycling batteries pyrometallurgically and each of the existing methods is unique to the company involved. Some facilities, such as Umicore, can process entire small-format batteries in their smelters. Alloy metals are recovered, which have greater market value than metal salts (as they require less processing to be returned to commerce). 5.2 Major Traditional Nickel and Lithium Battery Recyclers The EV battery recycling landscape is in a state of dynamic change. At present, there is a proven suite of established technologies for EV battery recycling at a well-established stage, an area of emerging technologies in very early market stages, and an aspirational ‘dream’ technology in the research stage. In traditional li-ion battery recycling, up to 40% of the materials are not recovered. “New” battery recycling technologies (none yet at scale) aim to recover up to 90%+ of the battery materials without pyrometallurgical processes, which are energy intensive. A research paper c o m p l e t e d by NREL in 2016 and published in 2018, identified 23 companies globally that recycled EVs in 2016: 12 in Europe; five in North America; and six in Asia.113 113 Mayyas, A., Steward, D., Mann, M. (2019). “The case for recycling; Overview and challenges in the material supply chain for automotive li- ion batteries.” Sustainable Materials and Technologies, 19. https://doi.org/10.1016/j.susmat.2018.e00087 KELLEHER RESEARCH STUDY ON REUSE AND RECYCLING OF BATTERIES EMPLOYED IN ELECTRIC VEHICLES FINAL REPORT SEPTEMBER, 2019 PAGE 48PDF Image | Reuse and Recycling of Batteries Employed in Electric Vehicles
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