How Toyota reduces emissions from battery recycling

Japanese manufacturer tests new treatment method without combustion and CO2 release

Photo by: Toyota

By: Riccardo Ciriaco

Feb 8, 2025 at 3:45am ET

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The goal is zero emissions, not just at the tailpipe, but throughout the life of the electric car, from the extraction of raw materials to the recycling of components. Toyota and its Chemical Engineering Division are working on a new way to recycle batteries without releasing greenhouse gases.

But let us take a step back. Today,' recalls the Japanese group, ' spent batteries are treated in an incineration plant, before the rare metals are collected and further processed. However,' he adds, 'the combustion process results in the loss of some recyclable materials and the production of large amounts of CO2.

More materials and less CO2

Instead, Toyota's engineers came up with a different system: "The electrolyte fluid in the batteries, which promotes the movement of the ions, is highly flammable".

"To eliminate the risk of fire during processing, this electrolyte fluid is distilled and extracted. The battery cells are then shredded, sorted and fed back into the production process. The recovered parts are large pieces containing aluminium or iron or the so-called 'black mass', a powder containing various rare metals. The recovered raw materials are then further processed by partner companies to produce new batteries".

Toyota tests a new recycling method for electric car batteries

Photo by: Toyota

New jobs

This could revolutionise an industry that needs to adapt to new EU rules to produce more batteries made in the EU.

"It is crucial to consider the life cycle of a car holistically", comments Yumi Otsuka, chief sustainability officer of Toyota. A more complete circular economy helps both to reduce CO2 emissions and to create new business opportunities'.

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