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Battery


ASCEND ELEMENTS SUPPLIES RECYCLED CATHODE MATERIAL TO FREUDENBERG

The US company Ascend Elements, which specializes in the production of battery
materials from black mass, has delivered its first recycled cathode material to
the US plant of German supplier Freudenberg e-Power Systems in Midland,
Michigan. The material is now being validated at Freudenberg for use in
commercial vehicle batteries.



Image: Ascend Elements
By Carrie Hampel
24.06.2024 - 16:00

 * Ascend Elements
 * Freudenberg Battery Power Systems
 * USA

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The delivered precursor materials (pCAM) and cathode active materials (CAM),
were obtained using Ascend Element’s “hydro-to-cathode” process, with which the
company aims to reduce the carbon footprint of new cathode materials for
electric vehicle batteries by up to 90 per cent. The 90 per cent reduction is to
be achieved by 2030. A life cycle analysis recently carried out by an
independent third party showed that the current reduction is as much as 49 per
cent.

Ascend Elements’ low-carbon cathode material will have a significant impact on
the carbon footprint of Freudenberg e-Power Systems’ batteries since cathode
material is the single largest contributor to a lithium-ion battery cell’s
carbon footprint.

With this process, Ascend Elements wants to be able to process the black mass
from recycled electric vehicle batteries directly into new cathode materials –
without the usual intermediate step of hydrometallurgically splitting the black
mass into the individual materials in order to then produce new cathode
materials. This should save up to 15 process steps.

The pCAM was obtained at Ascend Elements’ pilot plant in Westborough,
Massachusetts. The material was then sintered and processed into CAM at another
site in Novi, Michigan, before being delivered to the Freudenberg e-Power
Systems plant in Midland, also in Michigan. The German supplier acquired this
plant as part of the takeover of Xalt Energy. Xalt Energy manufactures cells,
packs and system solutions for heavy commercial vehicles and ships there, and
Ascend Elements and Freudenberg e-Power Systems announced their cooperation last
year.



Although Ascend Elements is still processing the material in Massachusetts and
Michigan, these materials will soon be produced in Kentucky, where Ascend
Elements is building the “Apex 1” plant, which will cost around one billion
dollars. This is due to go into operation at the beginning of 2025 and will
later produce enough pCAM and CAM for 750,000 electric vehicles per year.

“This is a relatively small shipment in relation to the intended full-scale
commercial program, but it’s an important milestone for Ascend Elements and the
US battery materials industry,” said Eric Gratz, PhD, CTO and Co-founder of
Ascend Elements.

The validation and potential use of recycled material in new batteries is not
only desirable and an important step from a sustainability perspective, but also
politically significant: cathode materials made from recycled battery metals can
help electric vehicle battery manufacturers qualify for US tax credits under the
Inflation Reduction Act (IRA).

“Battery manufacturers in the United States are starting to use engineered
battery materials that are made in America from recycled metals,” said Gratz.
“Engineered cathode material is normally made in Asia using material from mined
sources. Now we’re making it domestically from recycled EV batteries and
production scrap while generating just half the carbon footprint.”

ascendelements.com, freudenberg-eps.com





TAGS

 * Ascend Elements
 * Freudenberg Battery Power Systems
 * USA
 * Recycling
 * raw materials
 * Electric trucks


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