Production begins with the extraction of materials such as lithium, cobalt, nickel, and graphite. This takes place around the world and has a significant environmental impact due to mining activities. These raw materials are then processed into battery cells and assembled into complete battery packs, which are used in electric vehicles, among other applications.
Use and End of Life
A battery is expected to last between 10 and 15 years, and possibly even longer; however, real-world data is still limited. It is known that battery lifespan depends on technological developments such as improved battery management systems, the number of charging cycles, and how the battery pack is used. Once a battery is no longer suitable for use in a hybrid or electric vehicle, it can be repurposed for a second life in another application or recycled to recover critical materials.
Recycling: A Growing Sector
Battery recycling is playing an increasingly important role in Europe’s strategy for sustainability and raw material security. New regulations introduced in 2023 are encouraging higher recycling rates, helping to reduce dependence on primary raw materials and lower environmental impact.
Europe is developing a network of specialized recycling facilities, with Germany, France, and Sweden leading the way. In 2023, total European recycling capacity for EV batteries was 17,000 tons, but this is expected to increase to 290,000 tons by 2030.
How Does Battery Recycling Work?
Recycling EV batteries involves several steps to separate and reuse materials. Depending on the process, this may include one or more of the following steps, which take place at different companies:
Pre-treatment: discharging and dismantling EV batteries.
Mechanical processing: shredding components and separating materials.
Hydrometallurgy: recovering materials such as lithium, nickel, and cobalt through chemical processes.
Pyrometallurgy: melting batteries or material streams after mechanical processing to remove impurities and/or extract metals.
Challenges in Recycling Facilities
Pre-treatment (discharging and dismantling) in recycling facilities is labor-intensive and time-consuming. It also involves potential hazards due to the high voltage of the batteries, fire risk, and toxic substances that may be released.
As a result, interest in automated disassembly of EV batteries is growing. Robotic systems can dismantle battery packs faster and more safely than humans, improving both efficiency and safety in recycling operations.
Innovations in Automated Disassembly
Battery pre-treatment processes can initially be improved by building standardized data on battery design systems, enabling the digital collection of knowledge about specific battery types.
The next step is to automate the pre-treatment process. Research at RWTH Aachen University demonstrates how robots can unscrew battery packs and separate materials with reduced risk and shorter processing times. To make these technologies work effectively, standardized data on battery designs and recycling processes is essential. As a result, efforts are underway to better integrate this information into automation systems.
Innovations in handling the upcoming wave of waste batteries are crucial for working in a safer, more efficient, and more sustainable way.
