In an ever-changing world, sustainability has become a central concept that encompasses all aspects of our lives and the very survival of the planet. Companies around the world are adopting a more sustainable approach to their operations, and NCPOWER is no exception. In this article, we will explore what sustainability means, the different types of sustainability, and the key role played by the NCPOWER batteries in this important field.

What is sustainability?

Sustainability is a principle that refers to the ability to maintain and preserve a long-term balance in the use of natural resources, environmental protection, economic growth and social well-being. It involves meeting our present needs without compromising the ability of future generations to meet theirs. Sustainability is based on the idea that we should live within the limits of natural resources and not deplete them faster than they can regenerate.

What types of sustainability are there?

There are three fundamental pillars of sustainability, each of which plays a crucial role in building a sustainable future:

Environmental Sustainability

Environmental sustainability focuses on the conservation and protection of natural resources and the reduction of negative environmental impacts. It includes the responsible management of energy, water, biodiversity, waste reduction, care for flora and fauna, and the reduction of greenhouse gas emissions to curb climate change.

Economic Sustainability

Economic sustainability seeks equitable, long-term economic development that benefits both businesses and communities. This involves creating business models that are profitable but also socially responsible, avoiding the exploitation of finite resources and encouraging innovation and efficiency.

Social Sustainability

Social sustainability relates to equality, justice and people's well-being. It includes the promotion of gender equality, diversity, job security and access to education and health care for all. A sustainable society is one in which all people can prosper and have a good quality of life.

The Sustainable Development Goals and Agenda 2030

According to the Intergovernmental Panel on Climate Change (IPCC) report, global carbon dioxide (CO2) emissions must be reduced by 45% by 2030 and reach net zero emissions by 2050 to avoid the worst impacts of climate change.

In 2015, the United Nations adopted the Sustainable Development Goals (SDGs) as a universal call to action to end poverty, protect the planet and ensure that all people enjoy peace and prosperity by 2030. 

The 17 SDGs address a wide range of global challenges, from poverty eradication to climate action and gender equality. 

NCPOWER aligns with several of these goals through our sustainable products and practices.

The role of NCPOWER batteries in sustainability

NCPOWER batteries play a key role in promoting sustainability in several ways:

Environmental Sustainability

NCPOWER batteries are developed with a focus on energy efficiency and the reduction of pollutant emissions. This contributes to natural resource conservation and climate change mitigation by driving the adoption of electric vehicles and clean energy storage systems.

Renewable energy plays a crucial role in environmental sustainability. According to the International Renewable Energy Agency (IRENA), by 2050, 90% of the world's electricity will need to come from renewable sources to keep global warming below 2 degrees Celsius.

Economic Sustainability

By offering efficient and durable energy storage solutions, NCPOWER helps businesses reduce their energy costs and optimise their operations. This not only benefits businesses by improving their profitability, but also contributes to the economic stability of local communities.

Social Sustainability 

NCPOWER is committed to fair and safe labour practices, ensuring a positive working environment for its employees and partners. In addition, by driving the adoption of clean technologies, it contributes to job creation in the renewable energy sector and improves air quality and public health.

NCPOWER, moving towards sustainability through innovation

Technological innovation plays a key role in sustainability. Technologies such as the Internet of Things (IoT), artificial intelligence (AI) and advanced energy storage, such as NCPOWER batteries, are transforming industries and enabling more sustainable practices.

NCPOWER is firmly committed to sustainability in all its dimensions. Through innovation and commitment to responsible business practices, NCPOWER plays an essential role in building a more sustainable future for all.

In the search for more sustainable and environmentally friendly solutions, the circular economy and the green economy have become key concepts. These approaches aim to minimise the negative impact of our economic activities and encourage reuse, recycling and waste reduction. 

In this context, the role of lithium and its application in utility and commercial vehicles play a key role in moving towards a more sustainable future.

What is the circular economy?

The circular economy is an economic model based on maximising the value of resources throughout their life cycle. Unlike the traditional linear "use and dispose" model, the circular economy promotes the reuse, recycling and renewal of products and materials, thus avoiding the generation of waste and the extraction of new resources.

In this sense, the circular economy seeks to close material and energy cycles, keeping products, components and materials in use for as long as possible. It focuses on reducing waste production, optimising resources and promoting energy efficiency.

The role of lithium towards sustainability

Lithium has become highly relevant in the context of the transition towards a greener and more sustainable economy. As a key element in lithium-ion batteries, lithium has revolutionised the electric mobility sector, providing a cleaner and more efficient alternative to fossil fuels.

Lithium batteries offer a higher energy density, allowing for longer range and more efficient performance in the most demanding applications. electric vehicles utility and commercial vehicles. In addition, lithium has a longer life cycle compared to other battery technologies, which contributes to increased durability and reduced waste.

Implementation of the circular economy in commercial and utility vehicles

The circular economy finds a direct application in commercial and utility vehicles, where the optimisation of resources and the reduction of waste are essential. 

The incorporation of lithium batteries in these vehicles not only improves their performance and efficiency, but also enables the implementation of circular economy strategies.

In addition, the lithium industry has made progress in the implementation of battery recyclingThis allows the recovery of valuable materials such as lithium, cobalt and nickel. 

This contributes to closing material cycles, reducing dependence on the extraction of new resources and reducing the environmental impact of battery production.

European Battery Regulation

The new European Battery Regulation, the final text of which was agreed on 9 December 2022, aims to boost technological progress in the battery sector and minimise the environmental impact of battery production. 

It will gradually replace Directive 2006/66/EC and will be implemented in all EU member states from June 2023.

The main requirements of the new regulation are as follows:

  • Documentation: A European Battery Passport will be required, which will be an electronic document with an identification QR Code and a CE label. This passport will provide information on the carbon footprint of batteries and ensure their traceability.
  • CE marking: All batteries placed on the market must bear the CE marking, which indicates that the product complies with EU safety, health and environmental protection requirements.
  • BMS: from May 2024, all batteries will have to be equipped with a Battery Management System (BMS) to provide up-to-date information on battery status and expected battery life.
  • Carbon footprint: rules and methods will be established to quantify the carbon footprint of batteries, assessing the greenhouse gas emissions generated throughout their life cycle.

The regulation aims to ensure that batteries meet environmental, safety and traceability standards, thus promoting a circular and sustainable economy in the battery sector in Europe.

NCPOWER leading the way to sustainability

In this context of circular economy and green economy, NCPower is positioned as a benchmark in the development and manufacture of high quality and high performance lithium batteries for utility and commercial vehicles. 

Our commitment to the circular economy and the green economy positions us as a strategic partner in building a cleaner and more efficient future.

Recycling lithium-ion batteries is essential for sustainability: once they reach the end of their useful life, they must be disposed of correctly. In this sense, there are certain technical aspects to take into account in order to give a "second life" to this type of storage device. We will look at the key issues below, from the difference between physical and chemical processing to the different phases that are usually involved in the reuse of batteries.

Recycling processes for battery recovery: physical and chemical processing

Recycling lithium batteries involves various processes to recover the battery components and reduce the amount of waste. There are two main types of processes: physical and chemical.

1. Physical processes

Physical processes are a fundamental part of lithium battery recycling, as they are responsible for the pre-treatment of the battery components before chemical processes are carried out. These physical processes are based on the use of different physical characteristics of the materials present in the battery, such as density, magnetic properties and solubility, to separate the cathode and anode materials from other components such as current collectors and electrolytes.

One of the most common physical processes is the disassembly of the battery, where the different components of the battery such as the casing, electrolyte and current collectors are separated. Once separated, the components are crushed and undergo a separation process in which flotation, magnetic separation and density separation techniques are used to separate the different materials present in the battery.

In the separation process, battery materials are sorted into different fractions based on their physical properties. For example, casing material can be separated by magnetic separation, as it is attracted by a magnet, while heavier materials such as current collectors are separated by density.

2. Chemical processes

The chemical processes for the recycling of lithium batteries are based on the extraction of the active components of the battery through the use of solvents, reagents and acids that allow the separation of the different metals found in the battery, such as lithium, cobalt, nickel, manganese, among others.

Hydrometallurgical processes are the most widely used for the recycling of lithium batteries due to their selectivity in the recovery of metals and the reduction of toxic gas emissions compared to pyrometallurgical processes. Within hydrometallurgical processes, different techniques are used for the recovery of lithium battery materials. Some of these techniques are acid leaching, solvent extraction, electrowinning and chemical precipitation.

Pyrometallurgical processes are one of the most common forms of chemical processing for recycling lithium batteries. In this process, the metallic components of the battery are recovered by melting at high temperatures (typically between 800-1300°C), which allows the different metals to melt and separate. The metals are recovered in the form of alloys, such as copper, cobalt, nickel and iron, which can then be refined into high-purity metal components.

This process has the advantage of being relatively simple and productive for the recovery of metallic materials, but is not suitable for the recovery of organic materials. In addition, the slag resulting from the process may contain a variety of components, including metals and other materials, which can make it difficult to dispose of properly. 


lithium battery recovery processes
Fig. A Recycling processes and schemes [1]

The seven processes for recycling lithium batteries

In order to recycle lithium batteries efficiently and cost-effectively, we propose 7 key steps that are adapted to the complexity of the batteries and the recycling strategies of each plant. 

  • PreselectionBattery evaluation: In this process, an initial assessment of the batteries is made to determine their condition, size and type. It also checks for defective or damaged batteries that are not suitable for recycling.
  • Energy recoveryLithium cells or batteries contain energy and it is important to extract this energy safely before processing the battery for recycling. This process removes hazardous liquids and gases that may be released when the battery is handled.
  • DismantlingDismantling: In this process, the battery is dismantled to separate its components and parts. Most lithium batteries are dismantled manually, but some automated processes are also being developed.
  • DecontaminationLithium batteries contain hazardous chemicals, such as acids and heavy metals, which must be carefully treated to prevent their release into the environment. This process removes contaminating materials and decontaminates the battery parts. It includes cryogenic treatment, around -200°C, which prevents exothermic reactions during the later stages of the recycling process and/or pyrolysis and calcination heat treatments to remove organic and flammable components.
  • ReleaseOnce the battery has been disassembled and decontaminated, its components are separated. This process may involve crushing or grinding the battery into small pieces to facilitate separation.
  • SeparationSeparation: In this process, the materials that make up the battery, such as cobalt, nickel, lithium and iron, are separated. Physical and chemical processes are used to separate the materials and purify them for further use.
  • Metallurgical refiningOnce the materials have been separated, they are refined. This technique can be thermal (pyrometallurgical processes), chemical (hydrometallurgical processes) or even biological (biometallurgical processes).

Recovery of materials from the lithium battery

Comparing the two lithium battery recycling processes, and looking at pyrometallurgical vs. hydrometallurgical, what advantages does each offer?

  • Pyrometallurgical methods are more expensive in terms of energy and materials, but produce metals that can be sold. 
  • Hydrometallurgical methods can yield high quality materials for reuse in new batteries, making them potentially more efficient, but they are more complex and require more steps and chemicals.

However, hydrometallurgical methods have a significant advantage in terms of metal recovery. They can recover up to 100% of lithium and cobalt, 98% of manganese and 75% of aluminium in the form of cathode/anode materials ready for use in new batteries. However, this depends on whether the recycling process is profitable in terms of costs and revenues.

Fig. B: Example diagram of pyrometallurgical and hydrometallurgical processes for the recycling of NiMH, LMO and LCO batteries. [2]

The table below presents several examples of metals and products that can be recovered from end-of-life lithium batteries through different recycling processes. The table also indicates the purity that can be obtained from each of them, which ranges from 90% to 100%.

Fig. C: Summary of metals and chemicals obtained from recycling used Libs [3]

The table indicates that it is possible to recover both pure metals (cobalt, nickel, copper) and products usable to produce new cathode materials (carbonates, sulphates and hydroxides of various metals) from spent cathodes in different types of lithium batteries, such as LCO (LiCoO2), LFP (LiFePO4), LMO (LiMn2O4), NMC (LiNi1/3Co1/3Mn1/3O2) and NCA (LiNi0.8Co0.15Al0.05O2), through physicochemical processes.

The recycling process of the future

The recycling process currently used for lithium batteries involves obtaining the basic elements and compounds for the creation of new active materials from a "black mass". This black mass is a slurry of cathode and anode materials that still needs to be refined, resulting in a waste of energy and other materials.

Fig. D: Actual recycling process [1]

In order to improve efficiency, the aim is to switch to a "direct recycling" process. This aims to directly recycle the active materials as much as possible, avoiding the transformation into black mass and the need for refining and resynthesising the cathode and anode materials. This process also involves the implementation of collection systems based on the health of the modules and cells, which facilitates and speeds up the sorting phase.

In addition, the mechanical design of the batteries will take into account the disassembly that will take place at the end of their life, which will facilitate the disassembly in the recycling process. Active materials will be recovered and regenerated as far as possible, and only the non-regenerable part will be processed into primary components. 

Compared to the current process, direct recycling results in higher energy efficiency and a significant reduction of waste. Regenerated materials can be reused in the new cell production cycle, starting the cycle all over again.

Fig. E: Future recycling process [1]

To achieve optimal recovery in the recycling process, it is important to accurately select the materials to be recycled and their specific chemistry. To achieve this, the traceability of cells needs to be improved through technologies such as tags and RFID, which uniquely identify their composition and state of life. However, the recycling process is challenged by the ever-decreasing costs of cells, which requires more convenient and efficient recycling processes.

Currently, there are different recycling processes specialised in one type of battery to achieve high efficiencies. 

  • The Umicore and Sumitomo-Sony processes allow products that can be blended with virgin materials for use in new batteries without sacrificing their final quality.
  • The Recupyl process in addition to cobalt, allows the recovery of LiFePO cathodes 4 and LiPF electrolyte 6
  • Umicore-Valéas and Sumitomo-Sony processes electrolytes, plastics, organic materials, metals and graphite are not recovered for direct use but are partially used as by-products for the construction industry, thus devaluing their value.

Currently, recycling of LiFePO 4 and LiMn 2 O 4 batteries is limited due to their low market value, but these chemicals are increasingly being used in the energy industry. As the production of LiFePO 4 batteries increases, recycling is expected to increase and costs will be reduced. In addition, this type of battery is safer than other materials and its use is expected to expand in the future.

Fig. F: Battery chemistry market share forecast, 2015 - 2030 [4]

Second Life lithium battery: a solution that can be combined with recycling that should not be underestimated.

More and more studies are talking about giving a second life to end-of-life lithium batteries in electric vehicles. This solution involves recovering and reusing the spent battery for other purposes, such as energy storage, before recycling it. 

Re-use prolongs the overall lifetime of the battery and reduces the environmental impact of production, recycling and disposal. Depending on the type of use, the second life of a battery can last even longer than 10 years. 

In general, the practice of Second Life can extend the overall life of the battery and reduce its environmental impact, but its feasibility depends on the specific application and the uniformity of batteries on the market.

In the automotive sector, batteries are produced in large volumes and are more uniform, which facilitates the reuse of batteries at the end of their useful life for other purposes. 

NCPOWER lithium batteries? More and more attentive to the issue of recycling and sustainability

At NCPOWER we focus on sustainability in all aspects of our corporate vision, from the energy efficiency of our plant to the design of our batteries. 

The Research and Development department is central to this strategy, not only to anticipate customer needs with innovative products, but also to find more environmentally friendly solutions. 

NCPOWER uses LFP chemistry in its batteries, which is safe, stable and completely free of cobalt, a material that has a high environmental impact. In addition, the R&D department is actively studying more eco-sustainable production processes and materials in order to optimise the various production steps and the design of the batteries.

We know there is a long way to go, but NCPOWER is confident that investment in materials and skills aimed at efficiency and sustainability can make a big contribution on the road to a green society. 

Bibliography

[1] https://battery2030.eu/wp-content/uploads/2022/07/BATTERY-2030-Roadmap_Revision_FINAL.pdf

[2] https://pubs.rsc.org/en/content/articlelanding/2018/cs /c8cs00297e/

[3] https://doi.org/10.1016/j.jpowsour.2018.07.116

[4] Wood Mackenzie's energy storage service

Lithium batteries mainly differ from traditional batteries in their performance level, service life, energy profile and because they are virtually maintenance-free. But this is only part of their advantages. There is one more reason to switch to lithium and that is that this technology is much more environmentally friendly than the more familiar lead-acid batteries. 

While it is true that the application of lithium-ion batteries brings huge savings in operating costs and increased productivity for companies, another great advantage is that thanks to the low carbon footprint of Li-Ion technology, a large amount of energy is produced with low CO2 emissions. 

Undoubtedly, lithium batteries with NCPOWER System are more sustainable and environmentally friendly, as they are designed with eco-friendly technology developed by our R&D team that is constantly researching, testing and improving the development of our batteries to offer the best solution to the market and contribute to the care of the environment. 

In addition to the above, the recycling process of lithium batteries is becoming standardised and in the future it will be possible to reuse most of the raw materials of lithium batteries. In fact, Redux Recycling GmbH in Bremerhaven (Germany) are already technically able to reuse 70% of lithium-ion battery raw materials per year and recycle more than 10,000 tonnes. 

Lithium is no longer the future, it is the present. It's time to switch to lithium. Will you join this change and therefore take better care of our planet?