By Faridat Salifu
As electric vehicle (EV) manufacturers continue to make significant strides in diverting spent lithium-ion batteries from landfills, a crucial next step has emerged: reintegrating these batteries into a domestic supply chain for reuse.
This transition is essential for fostering a sustainable future in the automotive sector and reducing environmental impact.
A select group of specialized battery recyclers and refiners is now focusing on this vital phase, working toward establishing a closed-loop system that transforms recovered EV batteries into new ones on a large scale.
One of the leading companies in this initiative is Ascend Elements, which operates a facility in Georgia dedicated to processing battery materials.
At this facility, they grind down used batteries to produce what is known as “black mass,” a mixture of valuable metals that accounts for about half the weight of a typical battery.
Ascend Elements has ambitious plans to expand its operations, aiming to convert this black mass into two essential products for battery manufacturing: precursor cathode active material (pCAM) and lithium carbonate.
A new facility in Kentucky, scheduled to commence operations in 2026, is set to be the first of its kind in North America, furthering the company’s vision of a comprehensive recycling ecosystem.
This facility is expected to cater to major automotive manufacturers, battery producers, and cathode active material suppliers, solidifying its role in the EV supply chain.
With the surge in EV sales, the need for efficient recycling processes is becoming increasingly urgent. Industry experts project that a significant wave of end-of-life batteries will hit the market by 2030, presenting both challenges and opportunities for recyclers. Honda, for instance, is committed to making all its new vehicles electric by 2040.
Currently, the manufacturing giant offers two fully electric models in the U.S.—the Honda Prologue and the Acura ZDX. Honda’s strategy includes the rollout of additional models supported by an ambitious investment of over $1 billion in retooling three plants in Ohio. These plants are expected to begin producing EVs in late 2025.
Phil Cozad, North American Powertrain HaMat & Recycling project leader at Honda North America Services, underscores the company’s commitment to achieving “zero environmental impact” from its products and corporate activities by 2050.
To fulfill this challenge, Honda has introduced a strategy called “Triple Action to Zero,” which encompasses three core focuses: carbon neutrality, clean energy, and resource circulation. The third pillar—resource circulation—centers on recycling and reusing materials to effectively create new vehicles from older ones.
In order to facilitate this vision, Honda is actively collaborating with various recycling companies to establish robust battery collection systems that support its customers and dealers while advancing its environmental objectives.
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The company’s initial focus is on integrating recycled materials back into new batteries, with an emphasis on sourcing cathode active materials.
By establishing reliable channels for recycled materials, Honda aims to enhance its production capabilities while minimizing its ecological footprint.
This approach is not unique to Honda; many U.S. automakers are adopting similar strategies, recognizing the critical need for a sustainable supply of battery materials.
Original Equipment Manufacturers (OEMs) have a vested interest in ensuring they have access to the necessary battery materials to meet anticipated future demand.
As a result, they are increasingly working directly with mines and recycling companies to secure their supply chains for the next four to five years.
Ascend Elements is already making headway in this area. The company is currently supplying small batches of pCAM to a major EV manufacturer, which is conducting tests to validate the material.
As Ascend’s Kentucky facility prepares to come online, Frey anticipates a surge in interest from other automakers looking to establish similar partnerships.
“The push for recycled battery content will only grow as manufacturers seek to meet their sustainability goals and production demands,” Frey states.
In line with these efforts, Honda has secured agreements with both Ascend and Cirba Solutions to enhance its supply of recovered battery materials.
Other automakers are following suit; Toyota, Volkswagen, and Ford have partnered with Redwood Materials to work on building a domestic recycling supply chain. General Motors has also engaged with Lithion Recycling to leverage its advanced battery recycling technologies.
These partnerships illustrate the growing recognition across the industry of the importance of developing a robust recycling infrastructure.
As the EV market continues to expand, the initiatives being put in place by companies like Ascend Elements and major automakers are critical for creating a sustainable, closed-loop supply chain.
This system not only aims to minimize waste but also maximizes the use of recycled materials, ensuring that the future of the automotive industry is both environmentally responsible and economically viable.
By embracing recycling and resource circulation, the EV sector is taking significant steps toward a greener future, one where old batteries can be reborn into new vehicles, thereby supporting a circular economy.
