U.S. automaker General Motors has succeeded in recycling key minerals recovered from end-of-life electric vehicle batteries into new batteries. Batteries using recycled materials have also been installed in EVs for sale, demonstrating the potential for commercialising a circular battery supply chain.

CleanTechnica reported on Oct. 20 that GM completed a closed-loop recycling pilot project that reintroduced nickel, cobalt and manganese extracted from used batteries into new battery cells.

The project was carried out jointly with battery recycling company Cirba Solutions. GM collected 80 end-of-life EV batteries, dismantled and processed them, and converted them into black mass, an intermediate feedstock containing key minerals. It then refined the material to produce more than 12 tons of cathode active material. The nickel, cobalt and manganese used in the material were sourced entirely from recycled feedstock.

The recycled cathode material met the same quality and safety standards as new feedstock. Battery cells using the material also showed performance equivalent to existing products.

Ultium Cells, a joint venture between GM and LG Energy Solution, produced new battery cells using the material. The finished cells were assembled into battery packs at GM's Factory Zero and Spring Hill plants.

Vehicles fitted with the recycled batteries include 7 models, such as the Cadillac Lyriq, Vistiq and Escalade IQ, the Chevrolet Silverado EV and the GMC Sierra EV. These vehicles left production lines in September and entered the delivery stage to customers.

GM explained, "Recovering raw materials from used batteries can reduce reliance on new mineral mining and, over the long term, lower battery production costs and supply chain risks."

It is also running remanufacturing projects to extend battery life. It is reusing more than 70 percent of existing battery pack components and is also pursuing a project with Redwood Materials to use about 10,000 reused batteries in energy storage infrastructure.

Still, the recycling project is at an early demonstration stage. GM plans to expand its collection, refining and reproduction system to prepare for rising volumes of end-of-life batteries.