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leading battery manufacturers. The next step is to open a facility to process 5 tons/day of EOL EV batteries, scheduled to come on line in early 2020. 5.3 Developing EV Battery Recycling Technologies and Businesses Traditional li-ion battery recycling focuses on recovering the cathode metals (nickel and cobalt in 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. The metals recovered from the processes are sent to smelters for further recovery through pyrometallurgical processes. The recovery through the process is generally around an average of 50% measured by weight, but ranging from 40% to 80% depending on metal content and markets. A number of new recycling technologies are in development at this time with the expressed objective of achieving higher recovery (quoted by different companies as >90%) of various metals (nickel, cobalt, copper, aluminum, etc.), but ideally in a form suitable to sell directly back to battery makers, and without the pyrometallurgical step which is energy intensive. The approach used by these new companies is referred to as direct recycling or cathode-to-cathode recycling. Selling directly to end markets avoids having to send the batteries to smelters first, allowing the recycling company to make much higher revenues. The “new” recycling companies also claim that they will recycle the plastic and graphite. Discussions with Panasonic staff as part of this project indicated that the graphite used in battery production is so pure it would be unlikely that recycling back to batteries is viable, although the graphite might be used in other industries. Discussions with Li- Cycle staff confirmed that recycling graphite still needs considerable R&D. Some of the new companies will take the complete EV battery and tear it down to its various components (which will be recycled in traditional markets) and then take the cathodes to high value recycling, whereas other companies (e.g., American Manganese) are only interested in the cathode materials. Many new li-ion battery recycling technologies are at the R&D or early commercialization stage, but none are yet operating at scale. In general, details of the technologies used (mostly all hydrometallurgical processes) are not known and considered confidential. Numerous players are involvedin research in the area of recycling EV batteries to achieve higher yields (higher than the current 50% level). These include universities, combinations of universities and private sector companies, auto or battery companies, and government supported research in the US, Canada and overseas. KELLEHER RESEARCH STUDY ON REUSE AND RECYCLING OF BATTERIES EMPLOYED IN ELECTRIC VEHICLES FINAL REPORT SEPTEMBER, 2019 PAGE 62PDF Image | Reuse and Recycling of Batteries Employed in Electric Vehicles
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