As the global shift towards electric vehicles (EVs) accelerates and sustainability becomes paramount, the demand for efficient EV battery recycling is surging. Robin Brundle, Director and Co-Founder of Recyclus Group (Recyclus), offers a glimpse into the future of this industry.
How do you see the EV battery recycling industry evolving over the next five to ten years, and what role does Recyclus plan to play in that future?
The EV battery recycling industry is poised for transformative growth, especially with the push for standardisation across the automotive sector. As gigafactories and automotive companies align their efforts, we anticipate that standardised components will drive down costs and increase efficiency. Recyclus is preparing to meet this evolution head-on by ensuring our processes and plants are agile enough to comply with the upcoming 2030 EU regulations. We’re positioning ourselves to work closely with manufacturers, potentially co-locating with them to reclaim and recycle raw materials as they finalise their technology choices.
How is Recyclus involved in partnerships or collaborations to enhance its recycling capabilities?
We’re engaged in several strategic collaborations, especially with OEM battery manufacturers and automotive companies. We’ve already conducted trials on next-generation batteries, identifying key improvements such as the need for better discharge ports and easier fluid drainage from battery packs. On the output side, we’re partnering with a consortium to develop black mass separation capabilities in the UK.
This innovation will enable us to create a cradle-to-cradle recycling loop, ensuring sustainable use of materials like lithium, nickel, cobalt and manganese.
Can you describe the typical recycling process for an electric vehicle (EV) battery at Recyclus?
Our recycling process begins with discharging and dismantling the battery to ensure safety. Once that’s done, we shred the batteries in a controlled atmosphere using liquid nitrogen—a process that sets us apart by offering high recovery rates with minimal environmental impact. We then separate the materials, including valuable metals like lithium, nickel and cobalt, which are repurposed for new batteries, contributing to a circular economy.
How does Recyclus align its operations with broader sustainability goals, both within the company and globally?
Sustainability is at the core of our operations. We’re already working to meet the 2030 EU regulations ahead of schedule by refining our plant designs and processes. Additionally, recycling black mass could supply up to 45% of the UK’s battery material needs by 2035, significantly reducing our carbon footprint compared to raw material extraction. We’re committed to ensuring our practices contribute to greener technologies and the global push for sustainability.
What role does Recyclus play in educating the public and industry stakeholders on proper EV battery recycling?
We actively collaborate with the fire service to manage lithium-ion battery fires, sharing that knowledge with both the public and industry stakeholders. We also engage with government bodies like the House of Commons and Defra, contributing to policy development. Our goal is to drive greater awareness of the importance of battery recycling, ensuring that stakeholders at all levels are informed.
With the rise of second-life applications for EV batteries, how does Recyclus approach the balance between reuse and recycling?
While we initially invested in second-life applications, we’ve since shifted our focus to recycling. The emergence of sodium-ion batteries, which are more cost-effective and suitable for energy storage, influenced this decision. Recycling also offers better environmental and economic benefits, allowing us to recover materials that can be used to create new batteries.
Additionally, safety concerns in the grey market for battery replacements further validate our decision to prioritise recycling.
What challenges exist in repurposing EV batteries for a second life, and how does Recyclus navigate these?
Second-life applications present challenges, such as the need to become a certified battery producer, which carries significant obligations. Moreover, sodium-ion batteries are emerging as a superior alternative for energy storage, making second-life applications less appealing.
For these reasons, we’ve chosen to focus on efficient recycling, which allows us to reclaim valuable materials with fewer risks.
What is Recyclus’ current recycling capacity, and how scalable is your infrastructure to meet growing demand?
Our Wolverhampton plant has the capacity to process 22,000 tonnes of feedstock material annually. As demand for EV battery recycling grows, we’re prepared to scale by adding shifts and building additional facilities across the UK. Since we manufacture our own equipment, we can quickly adapt to future technologies, ensuring that our operations remain scalable and responsive to market needs.
How does Recyclus innovate in the recycling space? Are there any upcoming developments you can share?
Innovation is at the heart of what we do. We’re refining our plant to meet 2030 regulations, developing black mass separation technology, and expanding our award-winning mobile recycling solution. This mobile unit can safely dispose of small electrical items and process batteries on-site, providing a scalable solution for global markets like India, where lithium-ion recovery is currently limited. These innovations position us as a leader in sustainable, efficient recycling.
What advanced machinery and technology does Recyclus utilise, and how does it differentiate you from competitors?
We use liquid nitrogen for shredding and processing, a method that offers higher recovery rates and minimal environmental impact compared to competitors that use water-based techniques. This, along with our focus on precise black mass separation and advanced safety systems like remote monitoring and fire detection, sets us apart.
How does Recyclus minimise environmental impact and ensure regulatory compliance?
We’re committed to sustainability, using dry shredding methods in an inert atmosphere, recovering electrolytes efficiently, and maintaining minimal emissions. Our operations are designed to exceed regulatory requirements, ensuring both environmental protection and safety. With advanced monitoring systems and a focus on reducing our carbon footprint, we are leading the way in sustainable battery recycling.
To find out more, visit Recyclus Group
All images are courtesy of Recyclus Group