According to PR Newswire, Altilium, a UK-based clean technology company, has successfully produced the UK’s first electric vehicle (EV) battery cells using recycled cathode active materials (CAM) at the UK Battery Industrialisation Centre (UKBIC) in Coventry. This milestone marks a significant step toward circular economy solutions for EV batteries, reducing reliance on imported raw materials while cutting the carbon footprint of battery production.
The newly developed EcoCathode NMC 811-2036 CAM, derived from end-of-life EV batteries and Gigafactory waste, was processed at Altilium’s recycling facilities in Devon before being integrated into battery cells at UKBIC. These cells will undergo rigorous validation studies with a leading automotive original equipment manufacturer (OEM) to meet the EU’s Battery Regulations, which will mandate minimum levels of recycled lithium, nickel, and cobalt in new EV batteries by 2031, with stricter requirements by 2036.
Innovative Recycling Process and Environmental Impact
The Altilium recycling process begins with the dismantling and shredding of end-of-life EV batteries, producing a fine powder known as black mass. This material, rich in lithium, nickel, cobalt, and manganese, is then refined using Altilium’s proprietary EcoCathode process, which recovers over 95% of the critical battery metals. The extracted cathode metals are then upcycled into a high-nickel NMC 811 CAM, making them ready for reuse in new battery cells.
- Lifecycle analysis by Minviro found that Altilium’s recycled cathode materials reduce climate impact by up to 74% compared to using newly mined materials from China’s supply chain.
- Research from Imperial College London shows that batteries made from Altilium’s recycled materials match or surpass the performance of virgin materials, offering longer battery life, faster charging times, and lower production costs.
Scaling Up: Altilium’s ACT4 Recycling Plant in Teesside
Altilium is now focused on scaling up its operations, with plans to build the UK’s largest commercial EV battery recycling facility in Teesside. The ACT4 recycling plant will have the capacity to process 30,000 tonnes of CAM annually, meeting approximately 20% of the UK’s projected battery material demand by 2030.
This expansion will strengthen the UK’s domestic supply of sustainable battery materials, reduce dependence on mined raw materials, and support green industry growth. Altilium’s partnership with UKBIC is key to advancing the commercialization of battery recycling technologies, securing supply deals with OEMs and battery manufacturers, and reducing investment risks for large-scale production facilities.
Industry Collaboration and Future Outlook
Dr. Christian Marston, Altilium’s Co-founder and COO, highlighted that this milestone marks the first complete battery circularity achievement in the UK, ensuring that critical battery materials remain within the domestic supply chain. He emphasized that scaling up these innovations at UKBIC will position the UK at the forefront of sustainability and decarbonization.
Ameir Mahgoub, Head of Product Engineering at UKBIC, echoed this sentiment, stating that this breakthrough could pave the way for a new market in recycled EV batteries, reducing reliance on imported materials and supporting the transition to net-zero energy solutions.
As the UK and Europe ramp up their battery recycling initiatives, Altilium’s success at UKBIC demonstrates a scalable and commercially viable path toward a low-carbon, circular battery economy.
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