mpsc battery recycling overview - keynote address notes · 2021. 5. 7. · keynote address 2021...
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Battery Recycling OverviewKeynote Address2021 MPSC Battery Recycling Symposium
Renata Arsenault
Research and Advanced Engineering
Ford Motor Company
1
Outline
• A Changing World
• Why Recycle?
• Recycling Technology Overview
• Industry-Specific Challenges and Opportunities
2
Technology Curve Tipping Point
Supply Chain
New business
Models
Computing
Charging
Infrastructure
Renewables
AVs CE
Volumes
Costs
TE
CH
NO
LO
GY
CO
NV
ER
GE
NC
E
The battery’s
central role in
disruption
3
Soaring Demands for Cells, Rising Gigafactories and Battery Materials
Lithium-Ion battery manufacturing asset map
Fully Commissioned Under construction AnnouncedAutomotive industry is
the primary driver
Source: BNEF 4
Global Trade Flows and Battery Recycling Logistics
Without proper planning, there
could be short-term bottlenecks
in the supplies of some metals
needed for lithium-ion battery
production. This map shows
today’s trade flows of key
ingredients for battery
production, with exports from
each country shown in red and
imports in green.
Courtesy of the researchers
Will metal supplies limit
battery expansion?
Rise of electric vehicles and grid
storage may cause bottlenecks,
but no showstoppers, analysis
suggests.David L. Chandler | MIT News
Office
October 11, 2017
5
Current State: Depicted above
Ideal State: Localization of recycling…
and battery and raw material manufacturing
End-of-Life Battery and Manufacturing Scrap Projections
• > 3M tons EOL Li-Ion batteries by 2030
• Majority of volume from large format LIB
– Recycling mix today: 97% small format*
– Recycling mix 2030: 90% large format*
• Includes ~2-300 k tonnes battery
manufacturing scrap
• China volumes >> ROW, aggressive
expansion plans in Europe
• Recent trends favor local supply chains
and ramp-up of domestic recycling
Graphs Courtesy of Li-Cycle, 2020 6
>15 million tonnes
of LIB requiring
recycling by 2030
(cumulative)
Steadily increasing portion of
batteries requiring recycling
will be large format
Total Lithium-Ion Batteries Available for Recycling by Application/Sector (tonnes/year)
* BloombergNEF Jan. 2019 report:
Li-Ion Recycling: 2 Million tons by 2030
Total Lithium-Ion Batteries Available for Recycling by Region (tonnes/year)
Why Recycle?
• Product stewardship
• Protect people and the environment
• C-neutrality (corporate sustainability values)
• Source of conflict-free mineral provenance
• Regulatory compliance
• Sticks and carrots
• Secure critical materials for
supply chains under increasing pressure
• Supply chain circularity – critical link
• Energy security and national security
• Economics!
7
Battery Recycling Technology (Primer)
Process Categories and their Pros and Cons
Simple Separation Pyrometallurgical Hydrometallurgical Direct Recycling
Simple recovery of low value byproducts for down stream use
Breaks compounds down to elements. Further processing req’d
Breaks recovered material down to smaller building blocks
Secondary AM particles kept intact; surface purified and mat’l relithiated
• No (minimal) sorting• Accommodates mixed,
variable process feed • Low cost process• Resultant black mass easy,
cheap and safe to transport• Salable (indexed to LME)
• Very flexible• Simple, mature process• No sorting (within chemistry)• Accommodates diverse feed• Needs high price of Co and Ni• Favors high volume• Focuses on Co, Ni, Cu value• High purity product
• Flexible• No (minimal) sorting• Accommodates mixed
process feed • IN/OUT NMC ratios can differ• ~95% feed recoverable by wt• Can produce metal sulfates,
precursors or cathode
• Low fugitive emissions claims• May be good fit for
manufacturing scrap• Simple and low-cost process in
theory
• Low value product (example)
• Needs further refining
• Alloy requires processing to convert to battery materials
• Li cost to recover• CO2 generation• Permitting of new facilities• Costly treatment to avoid PFAS• ~ 50 % feed recoverable by wt
• Impurity removal challenges• Some sorting required for
most hydro processes
• Results to date all lab-scale• Sorting required• Impurity removal challenges• Likely to be inferior quality• IN=OUT chemistry limitation• Recovered material may still
need surface treatment
Low cost process, low value product: BLACK MASS
High purity, flexible, moderate value end product
Can generate basic building blocks, precursor or cathode
Promising economics but technically challenging and not flexible
PR
OS
CO
NS
8
Steps and Logistics of Battery Recycling
Form of recovered
materials varies according
to process design
9
Logistics Costs:
• Collection
• Storage
• Transport (multiple)
• Dismantling
Up to ~50% of total!
an example only…many variations exist
Regional Differences
Data source: BloombergNEF
US Europe Asia
Regional variations
$/ton
REGIONAL
DIFFERENCES:
• Transport. costs
• Labor costs
• Energy costs
• Material costs
• ESG factors
• Regulations
10
(
Regional Differences Favor Different Models
distributedcentralized decentralized
$
11
Many Business Models Possible…
12
EV
usersPack
Dismantling
Cathode
precursors
Battery
mfg.EV OEM
Metal
supply
Cathode
material
suppliers
Pack
Removal
TR
IAG
E
EV OEM
Indicate various
levels of
processing prior
to battery
manufacturing
REMAN
RE
PU
RP
OS
EBlack mass
Al, Fe, CuModule/Cell z
LiB Value Chain: Recycler Output Determines Downstream Customer
zMn
Co
Ni
Li
Conversion to
‘Black Mass’,
alloy or matte
Conversion to
lithium and metal
sulfates
Precursor/Cathode
manufacturing
Cell
manufacturing
Re
lativ
e
va
lue
bla
ck m
ass
or a
lloy
sulfa
tes,
lithiu
m
cath
od
e
Recycling
processes
have
different
outputsBlack mass or alloy
Metal sulfates, lithium compounds
Value added materials (precursor and cathode)
13
(
The Ideal State and the Challenges to Achieve It
IDEAL STATE
• Cost positive recycling (recovered value > collection, logistics and recycling costs)
• Intrinsic value drives collection
• Standard chemistry, standard formats (consistency)
• High volume
• Supply chain security and domestic circularity
FACTORS THAT INTRODUCE CHALLENGES
• Cost to recycle (requires measures to force or incentivize collection)
• Diverse chemistry or form factor
• Processes that require sorting
• Low volume
• Difficult dismantling
• Large size (specialized equipment needed)
• Lack of information (chemistry, SOH, shipping details etc.)
• High logistics costs (classification, distance, regional challenges) 14
Most of these will be MORE challenging for
DOD/military applications and may drive different optimal
solutions than those forautomotive.
Automotive vs Military
15
Battery removal
/ collection Transport
Storage
Dismantling
Discharge
DE
FE
NS
E /
MIL
ITA
RY
Transport Transport Transport
ADDED CONSIDERATIONS / CHALLENGES AT EACH STAGE RELATIVE TO AUTOMOTIVE
Loca
tio
n u
nkn
ow
ns,
d
ive
rse
che
mis
try
an
d f
orm
at.
No
relia
ble
in
fra
stru
ctu
re
Loca
tio
n u
nkn
ow
ns,
un
iqu
e
tra
nsp
ort
fa
cto
rs
(ta
nk,
se
a,
sub
ma
rin
e e
tc.)
Loca
tio
n u
nkn
ow
ns,
no
pre
dic
tab
le i
nfr
ast
ruct
ure
.
Pri
ori
tie
s: p
ass
iva
te a
nd
re
nd
er
safe
fo
r tr
an
spo
rt.
Loca
tio
n u
nkn
ow
ns,
un
iqu
e
tra
nsp
ort
fa
cto
rs
(ta
nk,
se
a,
sub
ma
rin
e e
tc.)
• Render safe
and easy to
transport
• Convert to alloy
or black mass?
• Maintain
ownership?
• Available
recycling?
• Transport
options? Loca
tio
n u
nkn
ow
ns,
un
iqu
e
tra
nsp
ort
fa
cto
rs
(ta
nk,
se
a,
sub
ma
rin
e e
tc.)
Gre
ate
r va
rie
ty i
n c
he
mis
trie
s
an
d f
orm
at,
le
ss e
con
om
y o
f
sca
le.
Less
sta
ble
su
pp
ly c
ha
in.
Loca
tio
n u
nkn
ow
ns,
un
iqu
e
tra
nsp
ort
fa
cto
rs
(ta
nk,
se
a,
sub
ma
rin
e e
tc.)
Va
lue
vs
ad
de
d c
om
ple
xity
of
fee
din
g i
nto
ow
n s
up
ply
ch
ain
Pyro
ShreddingHydro process
battery materialsCell
production
15
Enablers for a Sustainable and Efficient Recycling Ecosystem
sustainability
ba
ttery
size
16
17