In a quiet town in south-west England, a recycling lab gives old electric vehicle (EV) batteries a second chance. Inside the lab, workers shred used batteries into tiny bits. These broken pieces become a dark powder called “black mass.” Though it looks simple, this powder holds valuable metals that can be used again.
From Old to New
At the Altilium site in Tavistock, staff sort through black mass to remove unwanted materials like plastic and steel. What remains are key elements—lithium, cobalt, nickel, and graphite. These are crucial for making new EV batteries. Instead of throwing old batteries away, Altilium wants to reuse what’s inside.
This effort comes at a time when electric vehicles are growing fast. In 2023, one out of every five cars sold was electric, says the International Energy Agency. That’s a 35% rise from 2022. Today, 40 million EVs are on the roads. More cars mean more batteries—and more demand for the rare materials inside them.
Rare Resources, Big Challenges
Getting those materials is not easy. More than half of the world’s nickel comes from Indonesia. About two-thirds of cobalt comes from the Democratic Republic of Congo. Mining in these places often raises human rights concerns. This is why battery recycling is seen as a better option.
“These minerals are found in only a few places,” says Christian Marston, president of Altilium. He believes recycling helps countries like the UK rely less on imports.
A Lab in a Small Town
To reach Altilium’s lab, you drive through Dartmoor, a peaceful area with roaming sheep. The lab itself sits in an old shed across from a tyre shop. Inside, it’s high-tech. Tubes and glass cylinders hold colorful liquids—blue and green. Workers in white coats check each step of the recycling process.
This method is called solvent extraction. Altilium began working on it in 2020, but COVID slowed them down. By 2022, they had a working lab. Now they’re building a larger plant near Plymouth to recycle even more.
Only a few companies around the world recycle EV batteries. Some big names include Li-Cycle in North America and Redwood Materials in the U.S. These firms, like Altilium, aim to create a circular economy—where nothing is wasted and everything gets reused.
Why Recycling Matters
Many think old EV batteries end up in landfills. That’s not true, says Marston. Each used battery is full of useful metals. Recycling them stops these materials from harming the environment.
Other groups are also joining the effort. Redwood Materials works with carmakers like Toyota and BMW. Older companies, like Ecobat, are investing in recycling tech too. But experts say the field is still young.
“Battery recycling is just starting,” says Xiaochu Wei from Imperial College London. Last year, even BASF paused a big project in Spain.
How the Process Works
Each EV battery has two main parts—the cathode and the anode. When the battery is used, the anode sends out electrons that flow to the cathode. Charging the battery sends them back the other way. These parts are rolled up inside the battery, like a Swiss roll.
Altilium’s process starts by shredding the battery and pulling out the graphite from the anode. In the past, doing this required high heat, which produced a lot of pollution. Now, they use a water-based method with acid to separate the metals.
Once the black mass is soaked, workers filter out graphite and other low-value metals like copper and aluminium. These can still be sold to the construction industry. Then, they focus on high-value metals like nickel, cobalt, and manganese. By changing the acid levels and using special liquids, they pull each metal out one by one.
Tailoring for the Future
Battery tech keeps changing. Some companies now want more nickel for higher energy, while others move away from it to save money. Altilium adjusts their process to match what battery makers need.
“We aim to make a full loop for batteries in the UK,” says Marston. He wants a system where materials go from recycling back into new batteries—all without leaving the country.
Anna Hankin, a senior lecturer at Imperial College, agrees. She says batteries can only be refilled a few times before they must be taken apart. “Every battery will eventually need shredding,” she explains.
By reusing metals, recycling reduces the need for new mining. This is good for nature and people. Researchers think that by 2040, more than half the materials needed for EVs could come from recycled sources. In the next 10 years, recycling may meet up to 40% of the demand.
New EU laws starting in 2025 will require recycling targets. The rules will also set minimum levels for recycled content in new batteries.
Besides helping the planet, recycling helps nations stay secure. Global trade is shaky. Countries depending on imports face big risks. “Minerals mean power,” says Marston. “And we don’t have them.”
By keeping battery waste and recycling in the UK, he says, the country can hold onto more value.
Scaling up is tough, but Altilium has big plans. Their new plant near Plymouth will run non-stop. If all goes well, they’ll build two even bigger sites.
“If we scale recycling, we can cut costs by 20%,” Marston says. That could mean enough materials for 150,000 batteries a year.