Cirba Solutions, General Motors (GM), and their partners have completed a closed-loop EV battery recycling pilot designed to return recovered critical minerals from end-of-life batteries to the manufacturing process.
The programme involved processing used GM EV battery packs and recovering materials including nickel, cobalt, and manganese for use in new battery cells.
As part of the collaboration, Cirba Solutions disassembled and processed end-of-life GM EV battery packs at its lithium-ion recycling and recovery facility in Ohio.
The batteries were processed into Black Mass, a concentrated intermediate material containing critical minerals recovered through the shredding and processing of lithium-ion batteries.
The programme has resulted in the production of GM EV batteries using cathode active material (CAM) containing 100% recycled nickel, cobalt, and manganese.
The recycled materials were further refined into new CAM before being used to manufacture battery cells through Ultium Cells, the joint venture between GM and LG Energy Solution.
Speaking on the landmark EV battery recycling initiative, David Klanecky, President and CEO of Cirba Solutions, said: “Battery recycling is an important, intersecting component across the battery supply chain, and this programme effectively demonstrates the value that recycling end-of-life batteries brings to creating a closed-loop supply of critical minerals.
“The global battery supply chain is an interconnected network of innovative and collaborative organisations – and engaging in partnerships like this with GM shows us how this work can truly strengthen our supply chains, manufacturing, global competitiveness and national security.”
From battery waste to new cells
Recovering critical minerals is only the first stage of EV battery recycling.
Materials such as nickel, cobalt, and manganese can influence battery performance, meaning recycled materials must meet the same standards as virgin minerals before they can be used in new EV cells.
To achieve this, the partners further refined the Black Mass produced by Cirba Solutions.
The process showed that recovered minerals could be processed into CAM that met battery-manufacturing requirements, with the resulting CAM made entirely from recycled materials.
Ultium Cells then used the recycled CAM to produce new EV battery cells. GM manufacturing teams subsequently assembled the cells into battery modules and packs at GM’s Factory ZERO and Spring Hill assembly centres.
The first EVs powered by battery cells containing the recycled CAM have now rolled off the production line and are heading to consumers.
Melissa Flaherty, Director of Sustainable EV Battery Ecosystem at GM, added: “This pilot shows that the value of an EV battery can extend well beyond its first life, and that strong partnerships across the battery ecosystem are essential to building a more circular, resilient future for battery technology.”
Scaling closed-loop EV battery recycling
The project comes as the number of batteries reaching the end of their useful lives is expected to grow.
Nearly 14 million EV batteries are projected to reach end-of-life globally by 2040, while annual global demand for lithium-ion batteries is expected to reach approximately 4.2 to 6.8 terawatt-hours over the next decade.
This creates a growing role for EV battery recycling, allowing critical minerals recovered from used batteries to return to the supply chain and be used in new products.
The Cirba Solutions and GM programme also highlights the potential for domestic processing capabilities to support closed-loop models across other battery applications, including energy storage systems, data centres and consumer devices.
Recovering and reusing critical minerals could help support lower-cost batteries over time, reduce reliance on newly mined materials, advance manufacturing and strengthen supply chain resilience.
