Altilium Announces Breakthrough in Large-Scale EV Battery Manufacturing Using Recycled Materials

Photo Credit: Altilium

Altilium, a UK-based clean technology company focused on supporting the transition to a net-zero future, has announced the successful completion of initial tests on its first industrial-scale assembly of electric vehicle (EV) battery cells made from recycled materials. These tests were conducted at the UK Battery Industrialisation Centre (UKBIC), according to a company statement.

The company revealed that the electrochemical testing of these cells demonstrated performance comparable to those made from traditional primary materials. This development underscores the viability of using recycled cathodes as an alternative to mined metals, a significant step in the pursuit of sustainable battery production for electric vehicles.

The large-scale cell assembly trials, also reported by the company, showed that Altilium’s EcoCathode material was highly comparable in manufacturability to commercially available materials. No issues were reported throughout the entire manufacturing process, which was conducted at UKBIC’s state-of-the-art facility in Coventry, utilizing EcoCathode™ NMC 811-2036 CAM material produced at Altilium’s recycling facilities in Devon.

Altilium’s EcoCathode™ process, which can recover more than 95% of critical metals such as lithium from end-of-life EV batteries, was highlighted as a key part of this achievement. The process was shown to yield cathode materials with high consistency in manufacturing and electrochemical performance, in addition to its environmental and cost benefits.

According to initial electrochemical tests, Altilium’s EcoCathode materials demonstrated less than 1% variation compared to commercial benchmarks across key performance metrics. These results suggest that the recycled materials could be reintegrated into battery production without compromising performance.

The company also stated that process testing at UKBIC showed high equivalency between its EcoCathode material and the standard unit operations used in commercial battery assembly, such as mixing, coating, and formation. This suggests the material is well-suited for large-scale production.

Dr. Christian Marston, Altilium’s co-founder and COO, commented on the results, stating, “These results mark a pivotal moment for battery circularity in the UK. For the first time, we’ve demonstrated that battery grade EV cells can be manufactured at scale using recycled materials – with no compromise on quality or manufacturability.”

Richard LeCain, UKBIC’s Chief Technology Officer, expressed excitement about the initial findings, stating, “We’re thrilled with the initial results of these tests. This groundbreaking project marks the beginning of a journey that could reduce the UK’s dependence on imported materials and open up a new market for recycled batteries.”

The company’s next step involves conducting comprehensive validation studies with a leading automotive OEM to support regulatory and sustainability targets. Under the EU’s new Battery Regulations, all new EV batteries sold in the EU will need to include a minimum percentage of recycled lithium, nickel, and cobalt by 2031, with further increases required by 2036. Altilium’s battery cells are among the first to be manufactured in the UK in compliance with these new regulations.

Altilium is continuing to develop sustainable battery raw materials at its UK facilities, including the newly opened ACT 2 recycling facility in Plymouth, which is the first of its kind in the UK. The company is also constructing the ACT 3 scale-up plant, which will have the capacity to recover critical battery minerals from 24,000 EVs per year.

Recent research conducted by Imperial College London also confirmed significant improvements in the purity, morphology, and electrochemical performance of Altilium’s recycled CAM compared to commercially available materials. These enhancements have the potential to improve battery performance, offering longer lifespans, faster charging times, and reduced costs.

Altilium’s work in developing recycled battery materials is expected to play a crucial role in creating a sustainable EV battery supply chain in the UK, reducing reliance on imported raw materials, and supporting a greener, more resilient future.

Source: Altilium