In a significant leap towards sustainable automotive manufacturing, the UK has successfully produced electric vehicle (EV) battery cells from recycled materials, demonstrating a remarkable 32% reduction in greenhouse gas emissions compared to those made from virgin raw materials. This pioneering achievement, a collaboration between clean technology group Altilium and luxury car manufacturer JLR, was showcased at the Cenex Expo 2025, marking a crucial step in establishing a circular economy for EV batteries in the United Kingdom.
A Milestone for Sustainable EV Production
The breakthrough represents the first time full battery circularity has been achieved in the UK, from recovering critical minerals to manufacturing a new battery. Altilium, a UK-based clean technology group, partnered with JLR to demonstrate these innovative EV battery cells, which were produced using recycled cathode active materials (CAM). The manufacturing took place at the UK Battery Industrialisation Centre (UKBIC) in Coventry, showcasing the potential for recycled content in high-performance automotive applications.
The EcoCathode™ Process: How it Works
At the heart of this innovation is Altilium’s proprietary EcoCathode™ process. This technology begins with the dismantling and shredding of end-of-life EV batteries and Gigafactory waste to produce a fine powder known as “black mass.” From this black mass, Altilium’s process recovers critical metals, including lithium, nickel, cobalt, and manganese. The cathode metals are then “upcycled” into high-nickel CAM, which is ready for direct reuse in new batteries, while graphite is further purified for anode production. The EcoCathode™ process boasts impressive recovery rates, reportedly retrieving over 95% of cathode metals and more than 99% of graphite.
Significant Environmental and Economic Benefits
An independent Life Cycle Assessment (LCA) conducted by UK sustainability consulting group Minviro confirmed that using 100% recycled cathode active material for NMC 811 pouch cells manufactured in the UK could reduce greenhouse gas emissions by 32% compared to cells produced with virgin materials mined and refined in Asia.
Beyond carbon footprint reduction, the use of recycled CAM also led to considerable environmental advantages across several key areas:
- Particulate matter formation: 30% reduction.
- Freshwater ecotoxicity: 58% reduction.
- Metal and mineral resource depletion: 38% reduction.
These reductions highlight the comprehensive positive environmental impact of this recycling approach, moving towards a more sustainable and less resource-intensive battery manufacturing process.
Meeting and Exceeding Future Regulations
The recycled EV battery cells are already compliant with future EU Battery Regulations, which mandate minimum levels of recycled lithium, nickel, and cobalt in new EV batteries sold into the EU from 2031, with further increases in 2036. The concentration of recovered materials in Altilium’s cells – 26% cobalt, 12% lithium, and 15% nickel – meets the 2036 targets well in advance. This early compliance provides a significant advantage for UK carmakers, particularly for exports to Europe, and strengthens the domestic supply chain resilience.
Towards a Circular Economy for EV Batteries
This initiative is a critical component of the Advanced Propulsion Centre UK’s (APC) Advanced Route to Market Demonstrator (ARMD 3) program. Its primary goal is to prove that battery cells can be manufactured at scale using recycled content, delivering a crucial carbon reduction technology for Battery Electric Vehicles (BEVs).
By establishing a robust domestic supply chain for battery materials, the UK aims to reduce its reliance on imported raw materials, enhance energy security, and foster green industries within the country. Dr. Christian Marston, Altilium co-founder and COO, emphasized that this milestone is a “major technical breakthrough and a vote of confidence in the UK’s ability to lead in battery recycling.”
Performance and Future Validation
Initial electrochemical testing of the new automotive-grade NMC 811 multilayer pouch cells has shown their performance to be comparable to cells using conventional primary materials. These recycled cells are now undergoing comprehensive validation studies at JLR’s state-of-the-art battery testing facilities, ensuring they meet the stringent performance standards required by the automotive sector.
Dr. David Sellick, Product Sustainability Propulsion SME and JLR project lead, stated that the project “reinforces JLR’s leadership in sustainable innovation, marking a significant step forward in reducing the environmental impact of the largest contributor to an EV’s carbon footprint – the battery cell.”
Altilium is actively scaling its operations, with its ACT 2 facility in Plymouth already operational as the UK’s first commercial EV battery recycling site. The upcoming ACT 3 plant is expected to recover battery minerals from up to 24,000 vehicles annually, and a planned Teesside plant aims to process scrap from over 150,000 EVs per year, producing 30,000 metric tonnes of CAM. This significant expansion is projected to meet approximately 20% of the UK’s expected CAM needs by 2030.
