Battery Recycling Innovations
Identifying cutting-edge recycling technologies for a major EV manufacturer to deliver high metal recovery rates, minimal energy input, and virgin-grade output for a closed-loop supply chain.
Client
Major EV Manufacturer
Objective
Enable Closed-Loop Battery Production
Timeline
10-Week Program
Key Focus
Sustainability & Purity
The Challenge: Three Hurdles in Closing the Loop
As EV adoption accelerates, sustainable end-of-life management for batteries is critical. Next-generation recycling aims to recover high-value metals, but the field faces three intertwined hurdles.
Disassembly Complexity
Diverse pack designs, proprietary adhesives, and variable states-of-health complicate automated teardown and material sorting.
Energy & Carbon Footprint
Conventional pyrometallurgical pretreatment is highly energy-intensive, reducing the overall environmental benefit of recycling.
Material Purity Standards
Secondary feedstocks must meet or exceed virgin-grade specifications to satisfy automaker warranty and performance requirements.
Key Outcomes: A Blueprint for a Circular Supply Chain
Our 10-week analysis of 50 unique process variants produced a shortlist of pilot-ready solutions with compelling economic and environmental benefits.
>95%
Ni & Co Recovery
Achieved by a direct-cathode solvent process at <5 MJ/kg energy input.
60%
Reduction in Manual Labor
From a new cryogenic-delamination disassembly line.
40%
Reduction in CO₂ Emissions
Versus primary mining and refining, based on our environmental impact model.
Strategic Impact
Using our recommendations, the EV manufacturer launched two pilot facilities. Early results indicate metal outputs meeting OEM grade with a 30% reduction in processing energy. The roadmap positions the company to secure a sustainable, closed-loop battery supply chain, strengthening resilience against raw-material volatility.