Altilium, a UK-based clean technology group focused on supporting the transition to net zero, has announced initial test results for the first industrial-scale assembly of EV battery cells manufactured with its recycled materials at the UK Battery Industrialisation Centre (UKBIC).
In a major breakthrough for the development of sustainable battery materials, electrochemical testing of the cells has demonstrated comparable performance with cells made from conventional primary materials, underscoring the potential of recycled cathodes as a viable alternative to mined metals.
The large-scale cell assembly trials also showed a high degree of equivalency in the manufacturability of Altilium’s EcoCathode material compared to commercially available material, with no evidence of issues throughout the entire manufacturing process.
The pouch cells were successfully manufactured at UKBIC’s state-of-the-art facility in Coventry using Altilium’s recycled EcoCathode™ NMC 811-2036 CAM, produced at its recycling facilities in Devon.
The results underscore the potential of Altilium’s proprietary EcoCathode™ process, which is capable of recovering over 95% of critical metals, including lithium, from end-of-life EV batteries. The process has now been proven to yield recovered cathode materials which offer high manufacturing consistency and electrochemical performance, in addition to greater environmental benefits and lower economic costs.
Initial electrochemical testing of the cells produced at UKBIC has demonstrated that Altilium’s EcoCathode materials have the potential to be reintegrated into battery production with less than 1% variation compared to a commercial benchmark across key performance metrics. This highlights the exceptional consistency in the recycled material.
Cathode materials are critical components in lithium-ion batteries, and their performance is evaluated based on several key metrics, including energy density, first cycle loss, and cycle life. These metrics relate to both the overall performance of the cell and the overall cost for manufacture per kWh.
Altilium’s Ecocathode material compared favorably against the commercial benchmark material across initial formation behavior—attaining a similar first cycle loss, impedance, and initial cycling behavior.
Process testing at UKBIC also demonstrated high levels of equivalency between the typical unit operations used for the assembly of commercial batteries. Altilium’s EcoCathode material was shown to be processable under similar conditions across the manufacturing process, through mixing and coating formation and initial testing.
Dr Christian Marston, Altilium co-founder and COO, commented: “These results mark a pivotal moment for battery circularity in the UK. For the first time, we’ve demonstrated that battery grade EV cells can be manufactured at scale using recycled materials – with no compromise on quality or manufacturability. Our EcoCathode™ technology offers a viable, low-carbon alternative to mined materials and is now proven to work in real-world battery production. This is a major step toward a domestic, sustainable battery supply chain.”
Richard LeCain, UKBIC’s Chief Technology Officer, added: “We’re thrilled with the initial results of these tests. This groundbreaking project marks the beginning of a journey that could reduce the UK’s dependence on imported materials and open up a new market for recycled batteries. We’re excited to continue collaborating with Altilium as they drive this innovative project forward.”
The battery cells will now undergo comprehensive validation studies with a leading automotive OEM, supporting their regulatory and sustainability targets. Under the EU’s Battery Regulations, new EV batteries sold into the EU will need to contain minimum levels of recycled lithium, nickel, and cobalt from 2031, with further increases in 2036. Altilium’s battery cells are the first to be manufactured in the UK in compliance with the new regulations.
Altilium is developing the next generation of sustainable battery raw materials at its facilities in the UK, including its recently opened ACT 2 recycling facility in Plymouth, the first of its kind in the UK. The company has also begun construction on its ACT 3 scale-up plant, which will have the capacity to recover critical battery minerals from 24,000 EVs per year.
Previous analysis of Altilium’s recycled CAM by Imperial College London confirmed distinct improvements in purity, morphology, and electrochemical performance compared to commercially available materials. These benefits have the potential to deliver significant improvements in battery performance—including longer battery life, faster charging times, and lower costs.
Combined with the environmental benefits of using recycled materials, Altilium’s CAM looks set to be a key enabler in the development of a robust EV battery supply chain in the UK, offering cell manufacturers and automotive OEMs a sustainable domestic source of high-performance, low-carbon battery materials while reducing the UK’s reliance on imported virgin materials.
