What does sustainability mean in battery production?

How can the high demand for electromobility be made more sustainable?

European battery production currently accounts for around 17 percent of the global market. This share is set to rise to 26 percent by 2030 and many battery cell manufacturers have planned to expand their capacities in Europe. In particular, Northvolt, ACC, FAAM and Italvolt are planning major expansions.

However, most of the capacity comes from Asia, especially China and Korea, in particular from CATL, EVE, Samsung SDI and SK On.

Source: stock.adobe.com – Arif

European battery production brings with it a number of challenges, such as:

Each of these points is worth considering individually. But let’s first focus on sustainability in production.

Sustainability in battery production means taking equal account of ecological, social and economic aspects in order to minimise negative effects on the environment while maximising resource efficiency.

Aspect of raw material extraction

The increasing demand for batteries, particularly for electric vehicles and stationary energy storage, has led to a growing need for critical metals such as lithium, cobalt, nickel and manganese. However, these raw materials are often associated with significant environmental and social challenges. A sustainable approach to raw material extraction is therefore crucial to minimise negative impacts and ensure security of supply.

  1. Lithium is mainly extracted from salt lakes in countries such as Chile, Argentina and Bolivia, as well as from hard rock in Australia. Extraction from salt lakes requires large quantities of water, which can lead to water shortages in the regions and negative impacts on local ecosystems. Extraction from hard rock is energy-intensive and causes significant CO2-emissions.
  2. Cobalt is mainly mined in Congo, often under problematic conditions. Mining causes soil degradation, water and air pollution as well as the loss of biodiversity.
  3. Nickel is mined in various countries, including Indonesia, Russia and Canada. The mining and processing of nickel is energy-intensive and can lead to significant greenhouse gas emissions. The mines can also contribute to the pollution of water sources and the destruction of habitats.
  4. Finally, manganese is mined in countries such as South Africa, Australia and China. Mining leads to
    soil erosion, water pollution and can also result in a loss of soil fertility.

But the social impact must also be taken into account. Working conditions are precarious in many mining regions. Workers are often unprotected and work in dangerous conditions. Child labour and forced labour are also commonplace in some regions. Working in the mines is associated with considerable health and safety risks. The dust, chemicals and heavy machinery pose particular dangers. While the extraction of these raw materials often offers economic opportunities, it also often leads to social inequality and conflict. The local population is rarely the beneficiary and resettlement and environmental destruction often go hand in hand with extraction.

So what can you do?

It is about the responsible procurement of raw materials. By implementing transparency and traceability systems, companies can ensure that raw materials come from responsible sources. Certification systems, such as the Cobalt Refinery Supply Chain Due Diligence Standard, help to ensure compliance with social and environmental standards. But advances in technology can also improve efficiency and sustainability in the extraction of raw materials. Improved methods for extracting and processing lithium can reduce water consumption and CO2 emissions, while better recycling technologies can reduce dependence on primary raw material sources and reduce the need for newly mined metals.

Circular economy principles help to reduce the consumption of raw materials and increase sustainability. By recycling and reusing battery raw materials, the need for newly mined resources can be reduced.

Of course, governments play a crucial role in regulating the extraction of raw materials. Strict environmental and social standards and the enforcement of laws to protect the rights of workers and local communities are very important. 

Companies can achieve positive social effects through corporate social responsibility (CSR) initiatives and partnerships with NGOs and local communities. Investments in local infrastructure, education and healthcare help to improve the quality of life in mining regions.

There are initiatives and projects that have put such sustainable raw material extraction into practice. The Responsible Cobalt Initiative of companies such as Apple, BMW and Samsung aims to improve working conditions and environmental practices in the cobalt supply chain. By working with local communities and supporting certification systems, the aim is to minimise the negative effects of cobalt mining.

The Dutch company Fairphone is committed to fair and sustainable electronics production. Fairphone procures raw materials from conflict-free and responsible sources and is committed to transparency and ethical business practices throughout the entire supply chain.

In Project Lithium, for example, various research institutions and companies are working on projects to develop more environmentally friendly methods of extracting lithium. For example, research is being conducted into processes that reduce water consumption when extracting lithium from salt lakes.

Manufacturing process

The production of batteries is energy-intensive and can lead to significant COâ‚‚ emissions. In order to increase sustainability here, it is important to reduce energy consumption in production and rely on renewable energies. Some battery manufacturers are already doing this and relying on green energy sources such as solar and wind power to improve their balance sheet.

Innovative production techniques also help to reduce energy consumption. For example, advanced manufacturing processes such as the dry electrode process can significantly increase energy efficiency. The development of solid-state batteries, which are safer and more durable, also contribute to more sustainable battery production in the long term.

All steps from the extraction of the raw materials to the moulding process of the battery cells are extremely energy-intensive:

  1. The mining and processing of metals such as lithium, cobalt, nickel and manganese are energy-intensive and cause considerable COâ‚‚ emissions. The raw materials have to be cleaned, processed and converted into active materials such as cathodes and anodes.
  2. The manufacture of electrodes involves processes such as mixing, coating and drying, all of which require considerable amounts of energy. Drying the electrode coatings in particular is a very energy-intensive process.
  3. Finally, during cell assembly, the electrodes are joined together and installed in a cell structure. This step involves stacking or winding the electrodes and filling them with electrolyte.
  4. Finally, after assembly, the battery cells undergo a forming process in which they are charged and discharged for the first time. This process stabilises the cell chemistry and is also very energy-intensive. The cells then have to age, which requires additional energy.

The focus on renewable energies can therefore help to significantly improve the ecological footprint of batteries. Gigafactories that are powered by solar energy or production facilities that have been completely converted to renewable energy are good examples of this.

However, the individual production processes can also be optimised to contribute to an improved balance sheet. Traditionally, electrodes are produced by applying a wet paste to a carrier material, followed by an energy-intensive drying process. The dry electrode process eliminates this drying step and thus significantly reduces energy consumption.

3D printing enables the production of complex battery designs with high precision and efficiency. Additive manufacturing can minimise material waste and optimise production processes.

The use of more energy-efficient machines and systems in production can reduce overall energy consumption. Modern production techniques and automation can also help to optimise energy consumption.

Image generated with AI (Adobe Firefly) – The production of lithium batteries

Energy consumption can be further reduced by optimising production lines and reducing waste. Lean manufacturing and other efficiency-enhancing methods help to improve processes and minimise the consumption of resources.

Finally, new technologies can also help to improve the CO2 balance of batteries. Solid-state batteries, for example, replace the liquid electrolyte with a solid one, which increases safety and potentially improves the service life and efficiency of the batteries. The integration of recycling technologies into the production process can help to reduce energy consumption. Efficient recycling processes recover valuable raw materials and reduce dependence on energy-intensive new raw material extraction.

Sodium-ion batteries use sodium instead of lithium, which reduces dependence on critical raw materials and potentially requires less energy-intensive production processes. Sodium is more readily available and less polluting than lithium.

Organic batteries use organic compounds instead of metals as active materials. These batteries are more environmentally friendly and can be produced from renewable raw materials. They therefore also offer the possibility of developing fully recyclable batteries.

Recycling and circular economy

Another important aspect of sustainability is the recycling of batteries. Currently, only a small percentage of batteries are recycled. Efficient processes can help to reduce dependence on new raw materials and minimise the environmental impact.

A circular economy in which batteries are recycled and reused at the end of their service life is crucial for sustainability. The development of efficient recycling technologies, the creation of incentives for recycling, improved consumer information about the importance of battery recycling and appropriate collection systems must be established if progress is to be made. But we also need a new modular design for batteries, the avoidance of hazardous materials and the labelling of components. All of this contributes to an efficient circular economy.

There is a variety of battery types, including lithium-ion, nickel-metal hydride and lead-acid batteries, which require different recycling processes. Valuable metals such as lithium, cobalt, nickel and manganese can be recovered here. These metals are scarce and expensive, so recovering them makes economic sense and reduces dependence on primary raw material sources.

This diversity makes it difficult to standardise recycling processes. The batteries themselves consist of a variety of materials, including metals, plastics and electrolytes. Separating and recovering these materials requires advanced technologies and processes. Recycling, in turn, poses potential safety risks, including the risk of fires and chemical reactions. Special safety measures and technologies are therefore required to minimise these risks.

And ultimately, recycling can also create new business opportunities and jobs. Companies that specialise in the recycling and reuse of battery materials can benefit from the growing demand for sustainable solutions.

mechanical separation

In mechanical separation, batteries are first crushed, and the different materials are separated using physical processes such as magnetic separation and sieving. This method is efficient but is often only the first step in the recycling process. Hydrometallurgical processes use chemical solutions to extract metals from the battery components. The materials are dissolved in acids or bases and the metals are recovered through various chemical reactions. Hydrometallurgy is particularly effective in the recovery of lithium, cobalt and nickel.

pyrometallurgical process

In pyrometallurgical processes, the batteries are melted at high temperatures to separate the metals. This method is particularly useful for recovering cobalt and nickel but can lead to a higher environmental impact and requires energy-intensive processes. Direct recycling aims to reuse battery materials directly without breaking them down into their basic components. This could significantly increase the efficiency of the recycling process and improve the quality of the recovered materials.

However, it is also possible to extend the service life of batteries. The recycling, repair and reuse of used batteries from electric vehicles in stationary energy storage systems contribute to an effective circular economy.

The future of sustainable battery production is promising but requires continuous efforts and innovation. The development of new materials, optimisation of production technologies, promotion of recycling and the circular economy as well as political and regulatory measures can enable the battery industry to make a decisive contribution to the global energy transition and a sustainable future. Close cooperation between industry, research and politics is essential in order to overcome challenges and realise the full potential.

Dr. Ronald Hinz, Market Intelligence Senior Experte

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