Powder Processing for Batteries: EV Battery Manufacturing

In part, EVs owe their popularity to environmental stewardship.

30% of consumers say buying an EV aligns with their desire to live more sustainably.²

Virtually eliminating reliance on fossil fuels and substantially reducing carbon emissions appeal to eco-conscious consumers.

EV battery recyclability is another compelling reason — up to 95% of raw materials are recoverable,⁴ which bodes well for the environment and for EV manufacturers looking to capture and cost-effectively re-use materials and minerals.

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In countries currently supporting lithium-ion EV battery recycling, batteries are shredded and the plastic and metal remains are separated by size and composition. Minerals are then collected using one of two methods:

• Pyrometallurgy, which burns away non-metal materials to reveal transition minerals for retrieval
• Hydrometallurgy, which uses chemical solutions to recover transition minerals

Using these techniques, it’s estimated that by 2050 nearly 50% of nickel and cobalt, and about 25% of lithium can be recouped and used in EVs in the United States.⁵

The average lithium-ion EV battery weighs anywhere from 1,000 to 4,000 pounds, depending on the type. That’s literally tons of opportunity for sustainability and other initiatives that can be best leveraged by first understanding the components and powder processing behind EV batteries.

The structure of a typical rechargeable lithium-ion EV battery is very simple. There are three main components:

1. Anode (negative) stores energy. It determines battery capacity, cycle life, and lifespan. Graphite is the predominant mineral in the anode because of its electrical conductivity, stability, and capacity to store large quantities of lithium ions
2. Cathode (positive) receives charged ions from the anode. It converts the ions into engine power, which determines battery range. Lithium, nickel, cobalt, and manganese are found in cathodes since these minerals have high energy density and exceptional cycling performance
3. Separator sits between the anode and cathode, separating the two cells but still allowing them to exchange lithium ions

The simplicity of the battery structure can be misleading, and can foster consumer mistrust.

45% of consumers cite battery charge and travel distance as top concerns when considering an EV purchase or lease.²

The reality is that the components have little influence over battery technology. The interactions between the minerals housed within the anode and cathode are what define battery recharging and performance in key areas:

• Cycle: The number of times a battery cell performs at maximum capacity before dropping to 80% capacity, and then incrementally lower percentages
• Energy density: Measurement of the amount of energy a battery can hold in proportion to its weight (watt hours/kg)
• Power density: Battery energy discharge rate in proportion to its maximum capacity
• Charging time: How quickly a battery charges in proportion to its maximum capacity
• Reliability: Performance in relation to operating conditions, such as low temperatures or harsh environments
• Safety: Resistance to losing energy through self-heating/accelerated temperatures (thermal runaway)

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