In this episode of Balancing the Future from METTLER TOLEDO, we dive into the innovative world of electric vehicle (EV) battery recycling. Lead Engineer Dr. Jake Entwistle from Altilium Clean Technology shares insights from their UK pilot plant, which achieves over 90% efficiency in recycling "black mass" — the valuable powder left after shredding spent batteries. This black mass contains key metals like nickel, cobalt, lithium, manganese, and graphite, critical for manufacturing new EV batteries.
We explore the hydrometallurgical process used, which dissolves black mass in acids to separate valuable metals via impurity removal and solvent extraction, producing battery-grade materials. Dr. Entwistle highlights how recycling locally sourced materials reduces environmental impact by cutting energy use by more than 20% compared to mining virgin minerals, and helps secure supply chains for metals not mined in the UK.
The discussion covers evolving battery chemistries, such as NMC and LFP, and emerging technologies like lithium-sulfur batteries. We also examine the pilot plant’s role in scaling up these processes to commercial levels, processing about one EV battery per day, and the challenges of blending different battery chemistries and managing safety risks from toxic metals.
Dr. Entwistle emphasizes the importance of upcoming EU regulations mandating recycled content in EV batteries from 2031, driving demand for advanced recycling. The episode also touches on the EU Battery Passport for supply chain transparency, design improvements for easier recycling, and the broader goal of a circular economy in line with the European Green Deal.
Finally, Dr. Entwistle offers advice to aspiring scientists and engineers interested in battery recycling, encouraging hands-on experience and multidisciplinary collaboration to drive this sustainable technology forward.
Listen to the episode now on your favorite streaming platform: Spotify, Apple Podcasts, YouTube, Amazon Music.
Lead Engineer at Altilium Clean Technology
Dr. Jake Entwistleholds a Ph.D. in battery materials, specializing in high-capacity anodes and composite materials for lithium and sodium-ion batteries. Experienced in scaling lab innovations to production, he currently leads a UK pilot plant using hydrometallurgical recycling to upcycle Black Mass into active battery materials.
