Longer-Lasting EV Batteries Slow Ramp Up at Recycler Hydrovolt

Electric vehicle (EV) batteries are proving to be more durable than previously expected. This unexpected longevity is impacting the operations of Hydrovolt, a Norwegian recycling company that specializes in cell reprocessing. The company, which is owned by Norsk Hydro ASA, recently faced delays in ramping up its operations due to the longer lifespan of the batteries.

Hydrovolt's Recycling Facility

Hydrovolt operates a semi-automated facility located in Fredrikstad, Norway. This facility was designed with the capacity to handle around 12,000 metric tons of EV batteries, which is anticipated to come from approximately 25,000 electric vehicles each year. However, CEO Ole-Christen Enger has indicated that the company will only be able to process about one-third of that volume this year.

Electric Vehicles in Norway

Norway is at the forefront of the electric vehicle market, with battery-powered cars making up an impressive 95% of new passenger car sales in recent months. This high penetration of electric vehicles means that there is a growing need for solutions to address their end-of-life stages. Enger emphasized that while the market for recycling will eventually grow, the lifespan of modern EV batteries is extending significantly—often up to 18 years.

Current Challenges

The number of EVs being scrapped in Norway has increased by about 50%, reaching 3,662 between 2023 and 2024. However, battery-operated models accounted for only 4.4% of the passenger vehicles that were junked last year. The delay in recycling operations can be attributed to the durability of these batteries, which means fewer batteries are reaching the end of their life cycle.

Recycling Process at Hydrovolt

Hydrovolt began its journey by manually dismantling batteries to create secondary raw materials in 2022. This initial process laid the groundwork for the company's move towards a more automated approach. The batteries arriving at Hydrovolt’s facility come from various sources, including scrap yards, product recalls, and even batteries from ferries and stationary storage systems.

Battery Handling Safety

The recycling process is intricate, beginning with the complete draining of the battery's electrical charge. Automated forklifts then move the packs into designated bays, which are equipped with thermal cameras and specialized water beds to enhance safety. If a battery shows any signs of overheating, it can be quickly submerged and removed from the facility.

Material Recovery

After the battery casing has been stripped away, the materials are ready to be crushed. The outputs from this crushing process include valuable materials such as aluminum and copper, as well as a substance referred to as 'black mass', which contains critical valuable components. Hydrovolt is able to ship these materials safely across borders and plans for expansion, including a new facility in France for battery dismantling.

Future Partnerships

Originally a joint venture with Swedish partner Northvolt, Norsk Hydro has taken complete ownership of Hydrovolt after Northvolt filed for bankruptcy. As Hydrovolt moves forward, the search for new partnerships is underway to bolster its recycling capabilities and adapt to the evolving EV market.

EV, batteries, recycling, Norway, technology