Tag: planet pioneers

  • The World Needs to Crack Battery Recycling, Fast

    The World Needs to Crack Battery Recycling, Fast

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    Europe is slowly catching up, both in terms of battery production and recycling, with car manufacturers leading the charge to reclaim the valuable materials.The IEA forecasts that recycling could meet up to 12 percent of the EV industry’s demand for lithium, nickel, copper and cobalt by 2040.

    The Volkswagen Group—which includes Audi, Porsche and other brands—is recycling up to 3,600 batteries a year during a pilot phase at its new plant in Salzgitter, northern Germany. Mineral processors are also showing interest in entering the market: Australian minerals company Neometals has partnered with German company SMS group to build a battery-shredding industrial-scale plant, also based in Germany – a fitting choice of location, given that the country is Europe’s largest car manufacturer. 

    “Our sense of urgency to get recycling going is much higher than many people believe,” says Bo Normark, an industrial strategy executive at EIT InnoEnergy, a sustainable innovations accelerator funded by the EU. Lithium-ion batteries have a lifespan of more than ten years so it will take a while for them to pile up. But long before that—“actually, today,” says Normark—there will be a need for recycling scraps from battery production. These scraps include trimmings and other waste generated during the manufacturing process, or batteries that fail quality tests.

    But before battery recycling can be scaled up, the industry needs to rethink its approach. Today’s recycling methods are crude and designed to extract only high-value materials from the cells. Gavin Harper, a research fellow at the University of Birmingham, uses the analogy of the snakes and ladders board game to explain how lithium-ion batteries are currently produced and recycled. A player starts with raw materials at the bottom of the board, moves up the board to produce a battery and aims to end at the top of the board with a fully recycled battery. The snakes, which make a player slide down by several squares on the board, are of different lengths and correspond to various recycling methods.

    In a first step, recyclers typically shred the cathode and anode materials of spent batteries into a powdery mixture, the so-called black mass. In the board game analogy, this would be the first slide down on a snake, Harper explains. The black mass can then be processed in one of two ways to extract its valuable components. One method, called pyrometallurgy, involves smelting the black mass in a furnace powered with fossil fuels. It’s a relatively cheap method but a lot of lithium, aluminium, graphite and manganese is lost in the process.

    Another method, hydrometallurgy, leaches the metals out of the black mass by dissolving it in acids and other solvents. This method, Harper says, would correspond to a shorter snake in the board game, because more material can be recovered: you fall back, but not by as many squares as when using pyrometallurgy. The process, however, consumes a lot of energy and produces toxic gases and wastewater.

    “The Holy Grail for recycling is this idea of direct recycling, which only takes us a little way down the board,” says Harper. In simple terms: the cathode is separated out from the battery cell, regenerated in a chemical process and then placed back in a cell. “It’s certainly something that’s been proven as possible and that can work. There is a furious effort to research techniques,” says Harper, referring to the ReCell Center, an American research collaboration focused on battery recycling, and funded by the US Department of Energy. Similar efforts are underway in Britain and Europe.

    While some research institutes, companies and startups are trying to figure out how best to recycle lithium-ion batteries, others are working on cheaper and more sustainable types of batteries. Chinese manufacturers CATL and BYD are already producing lithium iron phosphate batteries, which are cheaper, less toxic, and cobalt-free. They are also banking on sodium-ion batteries – which use abundant sodium instead of relatively rare lithium – to become the next generation of EV batteries.

    Baker says that we should stop thinking about recycling as a process to mine precious metals out of a battery pack. “The value is not just the elements, it’s the combination of those elements, how they have been engineered and put together,” says Baker. In other words, to get battery recycling right, we might just need to completely redesign batteries from the ground up.


    Reaching net zero emissions by 2050 will require innovative solutions at a global scale. In this series, in partnership with the Rolex Perpetual Planet initiative, WIRED highlights individuals and communities working to solve some of our most pressing environmental challenges. It’s produced in partnership with Rolex but all content is editorially independent. Find out more.

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  • This concrete can eat carbon emissions

    This concrete can eat carbon emissions

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    Concrete: upon this rock-like composite we have built our church – and our houses, roads, bridges, skyscrapers, and factories. As a species we consume more than 4.1 billion tonnes of the stuff every year, more than any other material except water. (You’re almost certainly sitting or standing on it right now.) That’s a problem, because concrete – and in particular cement, concrete’s key ingredient – is catastrophic for the environment. The cement industry alone generates 2.8bn tonnes of CO2 every year, more than any country other than China and the US – and somewhere between four and eight percent of all global man-made carbon emissions.

    According to the Paris agreement, carbon emissions from cement production need to fall by at least 16 percent by 2030 for the world to reach its target of keeping global warming within the limit of 1.5C and well below 2C. (At present, those emissions are actually increasing, driven in large part by mega construction projects in China.) Now, the concrete industry is in a race against time to solve a very hard, very grey problem.

    The recipe for concrete has been largely unchanged since the 19th Century: you just need a mixture of large aggregate (stones), small aggregate (like sand), cement – which binds it together – and water. “The main issue with concrete is the production of cement, because if you want to get a cement, you need to have clinker,” explains Ashraf Ashour, professor of structural engineering at the University of Bradford. Clinker, typically a mixture of calcium carbonate, clay, and gypsum (although many other materials can be added) is mixed and heated in a kiln. “You need to heat clinker at a very high temperature, maybe at 1500 degrees, and by doing this, you are producing lots of CO2 emissions,” Ashour says. Inside the kiln, the clinker undergoes calcination: the calcium carbonate breaks down into calcium oxide, releasing even more CO2.

    One way to decarbonise concrete is to replace cement with other materials, such as the fly and bottom ash created by coal power stations, or blast-furnace slag, created in iron production. Cement makers have been mixing in waste aggregates for years, but with supplies constrained by the ongoing closure of coal plants, many companies are now exploring alternatives. Canada-based Carbicrete replaces the cement with steel slag, a byproduct of steel manufacturing. “There’s 250 million tonnes of it made every year,” explains Chris Stern, Carbicrete’s CEO. “For years, steel slag has basically been used for road fill. Some goes into roads, the smaller bits go into landfill, it’s sometimes used in fertiliser, but there’s not a huge usage rate.”

    Once concrete is mixed, it has to be hardened, or “cured”. Traditional concrete is cured with water, a process that takes 28 days. (When you see workers engaged in what looks like watering freshly-laid foundations, that’s curing.) Carbicrete’s concrete, however, is cured with carbon dioxide. CO2 captured from industrial processes is injected into the concrete, which reacts to form calcium carbonate, or limestone. “Right now, we’re a carbon negative company,” Stern says. “In fact, the actual marginal cost of capture is zero, because we can sell our product. That’s what makes [concrete] such an interesting product.”

    Another company hoping to scale CO2-cured concrete is New Jersey-based Solidia. Its cement uses less lime and more clay, including wollastonite (or synthetic pseudowollastonite) which lets Solidia fire it at a lower temperature. Solidia claims its method requires 30 percent less energy and produces 30 percent lower emissions. Its curing process also uses CO2, locking carbon up inside the finished product.

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  • A hidden Arctic cave holds secrets about our past and future

    A hidden Arctic cave holds secrets about our past and future

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    MOSELEY’S LOVE FOR caves began on a family camping trip to Cheddar, Somerset, when she was 12 years old. When an opportunity came up to take a guided tour of some local caves, she made her first foray into the dim, labyrinthine underbelly of the earth’s crust. Crawling about in the muck, she was instantly hooked: she started saving the money from her paper round so that on future holidays to Somerset she could disappear into those caves once more. “I just absolutely loved it,” Moseley says. “Other people might get the feeling if they go to Venice, and they wander around the alleyways, and want to know what’s around the corner – you know, that excitement. I get that when I’m underground.”

    Years later she started a PhD in paleoclimatology, which combined her two interests: caving, and climate change. Caves are valuable in climate research, because many contain speleothems: the collective name for geological features that are made out of mineral deposits, forming the stalagmites, stalactites and flow stones that hang from the cave roofs, or rise up like anthills from the floor. Speleothems grow slowly over millennia through the gradual drip of water from the outside world through the cave’s roof. Mineral calcite deposits form the physical structure, building individual hair-thin layers over time, somewhat like tree rings. “Each drop of water brings with it a chemical signature that can tell us about the processes going on at the surface at the time it was deposited,” Moseley explains. Calcite, oxygen, carbon, even traces of soil, pollen, and vegetation captured within, collectively build up a picture of past environments: what the carbon dioxide levels were in the atmosphere, the temperature, rainfall levels, and even the cave’s surrounding habitat.

    Meanwhile, the cave itself keeps this valuable record highly-preserved, making them portholes to the past. “[Caves are] well-connected to the surface environments, but also well-protected from the surface environment. What that means is that they’re sitting there beneath the surface, silently recording changes that are taking place over hundreds of thousands, even millions, of years,” Moseley says. This stable environment can generate long, detailed records of past climates that are largely intact. That’s compared to other climate archives like marine sediments which may be more vulnerable to disturbance by animals, or ice cores, which melt away when temperatures warm. “[Speleothems] really do tick many boxes, and provide some nice advantages as an archive type,” says Christopher Day, an isotope geochemist and paleoclimatologist at the University of Oxford, who is not involved in Moseley’s research.

    Advances in the uranium thorium radiometric dating used to analyse speleothems now allow researchers to date individual layers down to an accuracy of roughly 20 years. Paired with the environmental information they contain, “we can say with a lot of certainty when certain things happened,” Moseley says. She’s careful to emphasise that when it comes to climate records, speleothems are just one small part of a bigger picture but because caves are spread widely across the planet, their speleothems can help fill the gaps where other archive measures don’t exist. Meanwhile, their detailed records help build a richer global portrait of past environments. “You can gradually work towards a much more global representation of what the environment looked like, but with information that is specific to individual regions,” says Day. That helps researchers detect broad climate trends, and also compare the differences and relationships between regions, he explains.

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