UK-based clean technology group Altilium has produced the first EV battery cells using recycled cathode active materials (CAM) at the UK Battery Industrialisation Centre (UKBIC).
The production at one of the UK’s national battery manufacturing scale-up facility marks a breakthrough for recycled materials being used to produce new battery cells in an industrial environment in the UK. Altilium said it was an “important step towards the development of a circular economy for EV batteries”.
Pouch cells were manufactured at UKBIC’s facility in Coventry using Altilium’s recycled EcoCathodeTM NMC 811-2036 CAM, produced at its recycling facilities in Devon. By recovering critical metals from end-of-life EV batteries and Gigafactory waste, Altilium aims to reduce reliance on imported raw materials, but also cutting the carbon footprint of battery manufacturing, which would make EVs even greener as a transport choice.
Battery cells will now undergo comprehensive validation studies with an automotive OEM, supporting their regulatory and sustainability targets. Under the EU’s Battery Regulations, new EV batteries sold into the EU will need to contain minimum levels of recycled lithium, nickel and cobalt from 2031, with further increases in 2036.
Altilium’s battery cells are one of the first to be manufactured in the UK complying with the new regulations. Recycling begins with dismantling end-of-life EV batteries which is then processed with 95% of critical battery metals recovered. Cathode metals are then up-cycled to produce a high-nickel NMC 811 CAM, ready for reuse in a new battery.
Altilium’s planned ACT4 recycling plant in Teesside will have capacity to produce 30,000 tonnes of CAM a year – enough to meet nearly 20% of expected UK demand by 2030.
Dr Christian Marston, Altilium co-founder and COO, said:
“This milestone marks the first time full battery circularity has been achieved in the UK, from recovering critical minerals, including lithium, from end-of-life EV batteries and upcycling them into a high-performance cathode, to manufacturing a new battery for validation with a leading UK automotive OEM.
“Through this collaboration with UKBIC, we are moving beyond the emerging black mass recycling industry and ensuring that these critical battery materials remain in the domestic supply chain. Having access to a manufacturing facility like this allows us to scale up and develop this innovative work, which is helping to position the UK at the forefront of sustainability and decarbonisation.”
Ameir Mahgoub, UKBIC’s Head of Product Engineering, added:
“This pioneering project could be just the start of a journey that sees the UK becoming less reliant on imported materials and create a new market in recycled EV batteries.
“We look forward to collaborating with Altilium on this exciting project as they take it forward.”
Image courtesy of Altilium
