Altilium has calculated that using its recycled cathode and anode materials could reduce the carbon footprint of a new electric vehicle (EV) by 25.4%, compared to using virgin raw materials. The reduction marks an important breakthrough for automotive OEMs committed to decarbonising EV production and meeting their sustainability goals.

While EVs are pivotal in reducing greenhouse gas emissions, automotive manufacturers must also meet the challenge of reducing the environmental impact of battery production for a truly sustainable future. Altilium’s innovative recycling processes provide an answer to this challenge, by delivering the UK’s most sustainable battery materials and dramatically cutting GHG emissions associated with battery manufacturing.

EV batteries account for up to 40-60% of the embedded greenhouse gases in EV production. For a typical EV battery, that equates to around 7,500kg CO₂ equivalent. Of this, the cathode active material (CAM) is the largest contributor to the battery’s carbon footprint, accounting for over 50% of the emissions during production.

By recovering critical metals like lithium, cobalt, and nickel from old batteries, Altilium’s EcoCathode™ significantly lowers the need for mined materials. Mining and refining of raw materials accounts for about a quarter of total battery production emissions. Altilium’s EcoAnode™ process is also able to recover graphite, another critical component in lithium-ion batteries.

Based on the climate change impact of both processes, an EV battery produced using Altilium’s recycled cathode and anode materials could reduce those greenhouse gas emissions by over 50%, a saving of 3,806kg of CO₂ equivalent.

This is equivalent to saving over 20,000 miles driven in a typical petrol car, or the annual CO₂ emissions of approximately three petrol cars.

The calculations are based on a recent life cycle assessment (LCA) carried out by leading UK sustainability consulting and advisory group Minviro. The LCA found that NMC532 cathode produced using Altilium’s recycled feedstock could be up to 74% lower in climate change impact compared to the same cathode material produced using primary production in China, when assuming the primary nickel production route with the highest global warming potential in Minviro’s database.

In addition to cathode recycling, Minviro also looked at Altilium’s EcoAnode™ process. Minviro’s analysis shows that this process delivers a 77% reduction in GHG emissions for production of anode materials compared to primary production from China (assuming a supply chain route of synthetic graphite from Inner Mongolia).

By incorporating Altilium’s recycled materials, car manufacturers can take an important step towards reducing the environmental impact of EVs and combatting climate change. As demand for EVs continues to grow and the pressure to decarbonise increases, Altilium’s commitment to developing sustainable, domestic battery raw material supply chains will be critical in ensuring that the UK remains at the forefront of the transition to cleaner transportation.