Most old electric vehicle (EV) batteries don't end up in landfills. Instead, they enter a growing recycling industry or are repurposed for a second life as stationary energy storage. When an EV battery's capacity degrades to around 70-80% of its original state, it's no longer ideal for powering a car but still holds significant value for less demanding applications.
The most promising path is second-life use. These retired batteries can be collected, tested, and reassembled to store energy for homes, businesses, or the electrical grid. They can pair with solar panels or provide backup power, extending their useful life by 10 or more years before final recycling. Companies are already using them for everything from powering streetlights to stabilizing the power grid.
When recycling is the final step, the goal is to recover valuable raw materials like lithium, cobalt, and nickel. Advanced hydrometallurgical processes can achieve high recovery rates, reducing the need for new mining. The industry is moving toward a closed-loop system where materials from old batteries are directly used to build new ones.
Here’s a look at the material recovery potential from current recycling processes:
| Material Recovered | Typical Recovery Rate | Primary Use in New Batteries |
|---|
| Cobalt | 95% or higher | Cathode formulation |
| Nickel | 95% or higher | Cathode formulation |
| Copper | 95% or higher | Wiring and conductors |
| Aluminum | 90% or higher | Battery casing and tabs |
| Lithium | 70% - 90% | Electrolyte and cathode |
Ultimately, the fate of an old EV battery is a key part of the sustainability equation. While challenges in logistics and scaling up recycling capacity remain, the economic incentive to recover these valuable materials is driving rapid innovation, ensuring these power packs contribute long after their life on the road.
