Tech Insights

How Is the Industry Grappling With EV Battery Waste?

October 19, 2023 by Jake Hertz

As concerns over EV battery waste become more prominent, more and more organizations are exploring new approaches.

As electric vehicle (EV) adoption accelerates, with estimates suggesting over 43 million EVs on the road by 2030, the issue of battery waste becomes increasingly pressing. While the transition to electric vehicles promises reduced pollution and less dependency on fossil fuels, it also introduces waste management challenges that differ substantially from those associated with internal combustion engines. Addressing these challenges is crucial for the long-term sustainability of the electric vehicle industry. 


Waste metals in an EV battery.

Waste metals in an EV battery. Image used courtesy of Science (by Argonne National Laboratory)


Three recent studies reveal how researchers worldwide are approaching the challenge of EV battery waste.


Battery Recycling by Flash Joule Heating

Researchers at Rice University have developed a groundbreaking method for recycling metals from spent batteries.

In their study, the team employed a signature flash Joule-heating (FJH) technique to remove the inert layer on battery metals and lower their oxidation state. The FJH system employs a capacitor bank charged by a DC supply to provide electrical energy. The spent lithium-ion (Li-ion) batteries are first discharged, and the electrodes are collected. The cathode and anode wastes are mixed to form a "black mass," which is then subjected to FJH. The process achieves high metal recovery yields exceeding 98% and significantly reduces the time and resources needed for recycling. The method was then tested on various types of black mass to demonstrate its versatility.


A schematic of the battery recycling process.

A schematic of the battery recycling process. Image used courtesy of Chen et al.


Overall, the research provides a robust solution for the growing challenge of battery waste management, contributing to the mass production of electric vehicles at a more competitive cost. The method not only reduces the environmental footprint but also reduces the recycling process duration by almost 100-fold. The implications could be significant, especially as the EV industry gains more traction and more batteries are produced yearly.


France Uses Nuclear Know-How

In Europe, France is leveraging its expertise in nuclear technology to advance the recycling of materials in electric car batteries, solar panels, and wind turbines. 

Specifically, the French Atomic and Alternative Energy Commission (CEA) spearheads this initiative at its Marcoule research facility, a historically significant site for France's nuclear programs. The facility is applying techniques originally developed for recycling nuclear waste to recover lithium, nickel, cobalt, and graphite from spent electric vehicle batteries. One such method involves using hot acid solutions to dissolve metals extracted using organic solvents.

The CEA is exploring innovative techniques for other clean technologies. For instance, carbon dioxide is used to detach and inflate solar panel cells, enabling the recovery of silicon and silver. For wind turbine blades, "supercritical water" breaks down polymer chains in fiberglass or carbon composites. Additionally, the CEA is investigating extracting rare and valuable metals like palladium, rhodium, and ruthenium from radioactive waste.

This initiative aligns with the European Union's strategy to reduce dependency on Asia for critical metals and to compete with China's extensive recycling and raw material reserves. While the goal is to make recycled materials account for 35% of Europe's battery-making needs, complete self-reliance is not expected.


A More Viable Future for Electric Vehicles

The burgeoning electric vehicle market brings unique challenges, not least of which is managing spent batteries. As the global fleet of EVs is projected to swell into the tens of millions in the coming decade, the urgency to address battery waste is only increasing.


EV batteries in production.

EV batteries in production. Image used courtesy of Adobe Stock

Fortunately, researchers worldwide are rising to the occasion, devising innovative solutions that promise to mitigate environmental impact and offer economic advantages. Both the approaches discussed here underscore the importance of interdisciplinary research in tackling the multifaceted challenges of EV battery waste. They also highlight the need for global cooperation in sharing technologies and strategies. 

As the EV market expands, these research initiatives offer a roadmap for building a more sustainable and economically viable future.