Reuse and Recycling of Batteries Employed in Electric Vehicles

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Reuse and Recycling of Batteries Employed in Electric Vehicles ( reuse-and-recycling-batteries-employed-electric-vehicles )

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rated capacity of approximately 7,000 tonnes/year.127 In email correspondence during study research, Umicore representatives confirmed that 7,000 metric tonnes is the rated capacity on a yearly basis for processing li-ion and NiMH battery materials which include consumer battery material, automotive battery material, storage battery material and battery manufacturing scrap. Umicore does not comment on the actual throughput but can confirm that the majority of the material processed today is consumer type batteries and battery manufacturing scrap. The Hoboken smelting facility is an industrial prototype for Umicore to test out the technology. Umicore is committed to serve the end of life battery material industry as they supply cathode materials directly to battery manufacturers. When the flow of end of life batteries coming from the automotive applications reaches a critical quantity, Umicore will invest in larger facilities that would have capacities of 70,000 metric tonnes yearly in three regions: North America, Europe and Asia128. Umicore uses a combination of pyrometallurgy and hydrometallurgy to recover rare earth elements, cobalt, nickel, and copper from spent EV batteries. Umicore has four drop- off points for EV batteries in North America and a consolidation facility for EV batteries in Raleigh, North Carolina which accepts both NiMH and li-ion batteries from EVs of all types including buses and e- bikes.129 Dismantling of EV batteries is carried out manually in Umicore’s Hanau, Germany facility, to remove metals which can easily be recycled locally (steel casings and copper wiring). After pre- treatment and dismantling (to the module or cell level), battery packs and/or battery cells (depending on size) are consolidated for shipment to the Umicore facility in Hoboken, Belgium where they are processed in the Umicore smelter (which is a patented high-temperature design). Outputs from the smelter’s pyrometallurgical process include: • Slags, which include aluminum, manganese, lithium and rare earth metals; and • Alloys, which contain cobalt, nickel, copper and ferrous metal. Some slags are used in construction projects. Slag from li-ion batteries can be integrated in standard lithium recovery flowsheets, and slag from NiMH batteries can be processed to recover rare earth elements concentrate that is further refined through a cooperation with Solvay. Alloys (specifically designed for Umicore’s downstream hydrometallurgical process) are sent for alloy refining in Olen, Belgium and from there are sold to battery manufacturers to make active cathode materials for new rechargeable batteries.130 The smelter includes specially designed gas treatment (a confidential Umicore design) to ensure full dust removal and no formation of volatile organic compounds. Lithium is not currently recovered from the slag, as it does not make economic sense to do so. Should the price of lithium increase in the future, Umicore would evaluate additional processes to recover 127 Umicore presentation, March 2019, NAATBatt International Annual Meeting & Conference, Arizona, https://naatbatt.org/wp- content/uploads/2019/03/R1_MUP_Umicore.pdf. and confirmed through communication with Mark Caffaray of Umicore by email August, 2019 128 E-mail correspondence with Mark Caffarey, President of Umicore USA, August, 2019 129 Umicore. “E-mobility.” 130 Umicore. “Our recycling process.” KELLEHER RESEARCH STUDY ON REUSE AND RECYCLING OF BATTERIES EMPLOYED IN ELECTRIC VEHICLES FINAL REPORT SEPTEMBER, 2019 PAGE 54

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