UK consortium develops modular recycling system to recover EV battery metals domestically

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A group of UK companies is developing a new battery recycling system designed to recover critical materials from used electric vehicle batteries without relying heavily on overseas processing.

The initiative, called ReCAM, brings together the UK Battery Industrialisation Centre, Watercycle Technologies, Recyclus Group Ltd, and Polaron. The project focuses on processing “black mass,” the metal-rich powder that remains after lithium-ion batteries are shredded.

At present, much of the UK’s black mass is exported because domestic refining infrastructure remains limited. The consortium aims to process the material locally and convert it into reusable battery-grade materials.

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According to the group, the technology uses a “short-loop” refining process that reduces several conventional chemical stages. Instead of separating individual metals one by one, the system converts black mass directly into cathode active material used in battery manufacturing.

The process is designed as a modular system that can be deployed directly at recycling facilities rather than relying entirely on large centralised plants. Each modular unit can reportedly process around 250 kilograms (550 pounds) of material per hour.

The project comes as the UK prepares for a sharp rise in battery waste linked to EV adoption. Estimates cited by the consortium suggest black mass volumes in the country could reach around 94,000 tonnes annually by 2040.

The recovered material contains metals such as lithium, nickel, cobalt, and manganese, all of which are critical for battery production and global energy supply chains.

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Ahmed Abdelkarim said the project could help reduce export-related emissions while strengthening domestic battery supply chains.

Artificial intelligence is also being integrated into the process through Polaron’s materials platform. The company uses AI to analyse how processing conditions affect the structure and performance of recycled cathode materials, helping manufacturers assess whether recycled inputs can meet battery-grade standards.

Isaac Squires said the goal is to help recycled materials become suitable for large-scale reuse in future battery production.

The project is supported through the UK government’s Battery Innovation Programme, funded by the Department for Business and Trade.

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