The uncommon mineral predicament: Could 'eco-friendly batteries' emerge in the near future?
In the rapidly evolving world of electric vehicles (EVs), the focus on sustainability and resource efficiency is paramount. The EV industry, at the heart of electrification, is making significant strides to lower emissions and resource consumption in all four steps of battery production.
According to a study published in the Journal of Cleaner Production in 2022, battery remanufacturing through recycled materials can lower emissions during production by 51.8% compared to production with raw materials. This is a crucial step towards a greener future, as EVs require around six times the minerals used in a conventional car, with copper, lithium, nickel, manganese, cobalt, and graphite being some of the key minerals used.
The mining, refining, material production, logistics, and battery cell production are the four steps involved in obtaining rare minerals for EV batteries. However, the demand for these minerals is expected to increase significantly in the next two decades. To address this, the industry is introducing advanced recycling methods, such as water cooling, optimizing the electrode manufacturing process to reduce energy and material waste, and adopting faster and more precise quality control through advanced end-of-line and aging tests.
One such advanced solution is the CTP technology, which enhances space utilisation in battery packs by up to 60-80%, offering more excellent durability and lower costs in production. Another promising development is the research into next-generation technologies such as solid-state and sodium-ion batteries. Solid-state batteries (SSBs), for instance, can reduce the carbon footprint of an EV by up to 39% if recycled materials are used, according to Transport and Environment (T&E).
Hydrometallurgy is gaining importance as it increases the purity grade of recovered elements with lower energy consumption and no emissions. Recycled lithium battery cells offer around 17 times richer sources of nickel, up to five times more lithium, and ten times more cobalt than the mined ores, according to the Rocky Mountain Institute (RMI). This not only reduces the demand for new mining but also decreases the environmental impact associated with it.
The production of an EV battery emits up to 100 kg of CO2 equivalent per kilowatt-hour (CO2e/kWh). However, advanced solutions can eliminate up to 75% of emissions in the coming five or seven years through combined effort in all four steps of EV battery production. For example, the average amount of minerals used in a new renewable energy-generating unit has increased by 50% since 2010, according to the International Environment Agency (IEA). But with the focus on recycling, this trend can be reversed.
Recycling of used batteries could supply 10% of the demand for copper, nickel, lithium, and cobalt by 2040, according to the IEA. Another estimate by the Worldwide Wildlife Fund (WWF) suggests that recycling can fit 20% of the total market between 2022 and 2050, consistent with the IEA estimate.
Over 100 automakers have joined the Science Based Targets Initiative to manage and limit emissions in the EV industry. Regulations and initiatives from the European Union (EU) and the US, such as the CBAM and the Inflation Reduction Act, are also playing a crucial role in limiting GHG production in the EV industry.
One notable example of this is the Redwood Materials plant in Nevada, USA, which repurposes EV batteries with over 90% efficiency. This not only reduces the carbon footprint of battery production but also contributes to the fleet industry's goal of becoming zero-emission.
In conclusion, the EV industry is making significant strides towards a greener future. Through advanced recycling methods, optimized production processes, and research into next-generation technologies, the industry is working to lower emissions, reduce resource consumption, and create a more sustainable future for electric vehicles.
