Lithium-ion batteries could soon be made from recycled materials in the US

Lithium-ion batteries are the driving force in this increasingly electric economy. However, as lithium production reaches an all-time high, the problem of recycling these batteries to make new ones becomes even more prevalent. Now, in an effort to solve this issue, four leading battery companies—BASF, a global battery manufacturer; Nanotech Energy, a Florida-based specialist in graphene energy storage; American Battery Technology Company (ABTC), a Nevada-based expert in lithium-ion battery recycling; and TODA Advanced Materials, an Ontario-based producer of metal hydroxide materials—have joined forces to produce lithium-ion batteries using recycled materials.

How would the recycling work?

The recycling process will first begin with ABTC taking charge of recycling battery scrap and off-spec materials generated at Nanotech’s Chico, California facility. Once ABTC processes these materials, they will be handed over to TODA for the production of new precursors, marking the final stage before cathode production. Finally, BASF will take on the role of creating cathode-active materials at its new facility in Battle Creek, Michigan.

“Our partnership with Nanotech, ABTC, and TODA marks an important step for BASF’s global battery recycling business. Now, we are establishing the first closed-loop system in North America. This enables BASF and Nanotech to produce lithium-ion batteries with locally recycled materials,” said Daniel Schönfelder, BASF’s vice president of battery base metals and recycling.

Challenges surrounding battery production

As electric vehicle (EV) production continues to expand rapidly, the challenges associated with battery production become increasingly evident. These challenges include the substantial demand for minerals like lithium, nickel, cobalt, and manganese, as well as the e-waste crisis resulting from ageing EV batteries.

While this closed-loop system won’t be fully operational until 2024, this agreement marks a significant stride towards sustainable battery production. This is because incorporating recycled metals into new lithium-ion EV battery production could reduce the carbon dioxide (CO2) footprint of these batteries by an impressive 25%. Additionally, this process will alleviate the strain on finite mineral resources, diminishing the need for extensive mining and extraction.