GM and LG Chem's Ultium Cells Partners with Li-Cycle | Battery Recycling

Ultium Cells and Li-Cycle Partner for Battery Waste Recycling

Since its inception in December 2019, Ultium Cells LLC – a joint venture established by General Motors and LG Chem – has been progressively expanding its battery cell production capabilities within the United States.

However, the production of each battery cell inevitably generates waste materials. These materials present handling challenges and possess significant recoverable value, making landfill disposal an undesirable option.

Recycling Agreement with Li-Cycle

Instead of discarding this waste, Ultium Cells has entered into an agreement with Li-Cycle, a Canadian recycling company. This collaboration will focus on recycling critical materials derived from manufacturing scrap originating from Ultium’s Lordstown facility.

The recycling process is scheduled to commence later in 2021, with materials being transported to Li-Cycle’s processing center in Rochester, New York. The recovered materials will then be reintroduced into the battery supply chain.

Scale of Waste and Production Capacity

General Motors and LG Chem are committed to increasing their battery cell manufacturing output. Approximately 5-10% of a cell manufacturer’s production typically consists of excess scrap.

Given the Lordstown facility’s projected annual capacity of 35 gigawatt-hours – comparable to Tesla’s Nevada factory – a substantial volume of waste material is anticipated.

Li-Cycle’s Innovative Recycling Approach

Li-Cycle’s recycling methodology differs from conventional methods, as explained by co-founder Ajay Kochhar. Traditional recycling often employs pyrometallurgy, a high-temperature process.

This involves incinerating batteries to eliminate plastics and electrolytes, resulting in a raw material recovery rate of around 50%.

In contrast, Li-Cycle utilizes a low-temperature mechanical process. This involves shredding battery materials in a proprietary solution, similar to a paper shredder.

This approach minimizes the risk of fire and achieves a material recovery rate of up to 95%. Furthermore, it avoids the harmful emissions associated with burning plastics.

Comparison with Redwood Materials

Li-Cycle positions itself as a distinct alternative to competitors like Redwood Materials. However, both companies ultimately employ hydrometallurgy for battery processing, according to a Redwood spokesperson.

Redwood Materials also reports a recovery rate ranging from 95% to 98%.

Material Recovery and Circular Economy

The cathode and anode materials are transformed into battery-grade chemicals, including lithium carbonate, nickel sulfate, and cobalt sulfate. Li-Cycle collaborates with Traxys, a company specializing in the procurement of these chemical materials.

These recovered chemicals are then reintegrated into cathode production and the broader battery supply chain, contributing to a more sustainable circular economy.

The ultimate goal is to establish a “true circular economy closed loop,” where manufacturers can reclaim and reuse the same materials in their production processes.

Li-Cycle’s Facilities and Capacity

Li-Cycle currently operates two recycling “spokes” – facilities focused on shredding and mechanical separation – in Rochester, New York, and Ontario, Canada.

A third commercial facility is under construction in Arizona, which will increase Li-Cycle’s annual processing capacity to approximately 20,000 metric tons, equivalent to 4 gigawatt-hours of lithium-ion batteries.

Additionally, a “hub” is being built in Rochester to produce battery chemicals, with an annual capacity of 60,000 metric tons of battery scrap and “black mass” – a mixture of cathode and anode material.

Partnerships and Future Expansion

Li-Cycle collaborates with 14 automotive and battery manufacturers, as well as auto dealers and recyclers, to collect and process spent lithium-ion batteries.

Ultium Cells announced a second $2.3 billion battery factory in Spring Hill, Tennessee, scheduled to open in 2023. It remains uncertain whether Li-Cycle will also process waste from this new facility.

Recycling of R&D Scrap and Emerging Technologies

Li-Cycle also recycles research and development scrap from various automakers, providing the company with early insights into upcoming battery technologies.

This allows Li-Cycle to adapt its recycling processes to accommodate new battery chemistries, such as solid-state or lithium iron phosphate (LFP) batteries. The company already processes LFP batteries and plans to convert the phosphate into a fertilizer additive.

A Step Towards Sustainable EV Production

Kochhar emphasizes that this partnership serves as a demonstration of the economic and environmental benefits of electric vehicles.

He believes that this collaboration will prove that EV batteries will not end up in landfills, highlighting their inherent value and the availability of environmentally responsible recycling technologies.

Note: This article has been updated to provide clarification regarding Redwood Materials’ recycling process.