Progress in the development of a circular economy for electric vehicle (EV) batteries in the U.K. is reported by Altilium and Jaguar Land Rover, collaborators using recycled cathode active materials (CAMs) to produce EV battery cells.

The multilayer pouch cells were manufactured using CAMs recovered from end-of-life EV batteries using Altilium’s EcoCathode process, an approach that dissolves battery materials in aqueous solutions. Selective leaching, advanced filtration and proprietary purification techniques are then applied. The hydrometallurgical scheme supports the selective recovery of lithium, nickel, manganese, cobalt and iron phosphates at high purity, lower temperatures and with reduced carbon dioxide emissions relative to conventional smelting paths.

The concentration of recovered CAM meets the 2036 target for minimum recycled content levels specified in the EU’s new battery regulations (26% cobalt, 12% lithium, 15% nickel). Electrochemical testing of multilayer pouch cells produced with the recycled CAM demonstrated comparable performance with battery systems composed of conventional primary materials.

EcoCathode technology, which recovers more than 95% of the cathode metals from battery waste and more than 99% of the graphite, also offers reductions in metal/mineral resource requirements and in particulate matter formation of 38% and 30%, respectively.