Electric vehicle battery recycling is gaining significance as the number of electric cars increases. Mercedes-Benz is piloting a new plant focused on efficient battery recycling to recover up to 96% of materials, enabling a sustainable closed-loop system. Experts highlight the need for innovative processes, like hydrometallurgy, to reduce energy consumption and material loss. As the industry anticipates a growing recycling market, investments are vital for future success, while regulations and logistics remain critical challenges.
The importance of battery recycling for electric cars is on the rise as the vehicles age. Experts predict that the recycling industry could become economically viable by 2030. Mercedes is currently testing an environmentally friendly recycling process at a pilot facility.
The Vice-Chancellor may have wished to visit Kuppenheim in Baden-Württemberg, where his ministry is backing a significant project aimed at advancing battery recycling for Mercedes-Benz. The Chancellor’s personal attendance at the inauguration of the new Mercedes pilot plant underscores the need for positive news in the automotive sector, which has been scarce lately.
According to the Federal Motor Transport Authority, Germany currently has over 1.5 million fully electric vehicles and nearly one million hybrid models. This creates a substantial demand for batteries, which are the most expensive and vital part of electric vehicles, fueling the drive for sustainability.
Yet, batteries present significant challenges for electric mobility and greatly influence the ecological footprint of these vehicles. Manufacturing electric car batteries relies on precious metals such as lithium, nickel, and cobalt, leading to heavy reliance on international sources that can be problematic. Consequently, many experts advocate for a strong emphasis on recycling used batteries.
Public skepticism about electric vehicles has been an obstacle to the overall transition in transportation.
The Goal: A Circular Economy
Currently, a variety of recycling methods are employed. While pyrometallurgical techniques, which melt batteries at high temperatures, are commonly used, they are energy-intensive and result in significant material loss, along with harmful emissions. In contrast, hydrometallurgical processes, which use water and chemicals to dissolve metals and recover materials, require less energy and yield better results.
Mercedes is focusing on these innovative recycling techniques in its new Kuppenheim facility, aiming for up to 96 percent material recovery. Helmut Ehrenberg from the Karlsruhe Institute of Technology emphasizes that the pilot plant is designed not just to recycle materials but also to ensure they can be repurposed for new electric vehicle batteries. Initial laboratory tests have shown promise, and the next phase involves scaling the process for industrial application.
The market for used electric vehicles is gradually beginning to grow, but several factors contribute to its slow expansion.
“100 Percent Recycling Is Unrealistic”
“We need to transition towards a closed-loop system to promote sustainability,” states Ehrenberg. This is especially crucial for electrifying truck fleets, which consume more raw materials than passenger vehicles. However, he also argues that “100 percent recycling doesn’t make practical sense,” even if it could be achieved technically. Such a process could become so costly and energy-heavy that it would no longer be viable economically or ecologically.
Ehrenberg believes that the overall environmental balance is key. Recovering materials is just one aspect; it is equally vital to consider the energy and resources required for processing and the quality of the output materials. Achieving a genuine circular economy for car batteries only happens when corresponding battery cells can be effectively rebuilt. Mercedes-Benz has committed to investing tens of millions of euros in Kuppenheim, with a goal to produce over 50,000 new battery modules for fully electric cars annually.
An electric vehicle battery can use up to nine kilos of lithium and 13 kilos of cobalt.
A Collective Industry Focus
Other companies, including Duesenfeld in Lower Saxony, Accurec in North Rhine-Westphalia, and BASF in Brandenburg, are also working on enhancing recycling methods. Volkswagen has had its pilot plant in operation since 2021. As the demand for battery recovery continues to grow, a study from RWTH Aachen University and consulting firm PricewaterhouseCoopers predicts that by 2035, around 30 percent of the lithium, nickel, and cobalt in batteries could come from recycled materials.
Achim Kampker from RWTH Aachen, a co-author of the study, suggests that this percentage could climb to 60 percent by 2040. He believes that recycling will become profitable for European markets by 2030, especially as the number of used batteries increases. Although electric car batteries can last for a decade or more, the current return rates in Germany are still relatively low.
Investing in recycling facilities now is crucial to prepare for the future, Kampker insists, especially as China leads the way in this field. The EU’s new battery regulation, effective this year, provides a solid foundation for progress. Nonetheless, Kampker highlights the importance of political support in establishing favorable conditions for battery recycling logistics, including the transportation of potentially hazardous used batteries.
Stay tuned for more coverage on this subject on October 28, 2024, at