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Released April 07, 2025 | SUGAR LAND
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Researched by Industrial Info Resources (Sugar Land, Texas)--The rise of electric vehicles (EV) and battery energy storage systems for power generation has opened the door for lithium-ion battery recycling as part of a circular supply chain to help meet demand for critical minerals. Industrial Info is tracking $5.5 billion worth of capital-spending lithium-ion battery recycling projects in the U.S.
In general, after batteries are dissembled and shredded, the result is "black mass," which can contain high amounts of lithium, cobalt, manganese and nickel. These materials can be extracted from the black mass and reused for new batteries or other applications.
About half of the total investment value of lithium-ion battery recycling projects in the U.S. is attributed to two projects underway from Redwood Materials Incorporated (Carson City, Nevada), to support the development of two circular battery recycling and material production campuses.
Redwood is at work expanding its campus in Carson City, where it operates the largest lithium-ion battery recycling facility outside of Asia. The expansion project entails constructing a 550,000-square-foot building and installing new equipment so the site can ultimately produce 35,000 metric tons per year of battery-grade copper foil and 100,000 metric tons per year of cathode active materials (CAM) using both new and recycled feedstocks. Site preparation is underway, and the project is expected to wrap up in 2028. Subscribers to Industrial lnfo's Global Market Intelligence (GMI) Metals & Minerals Project Database can click here to read the detailed project report.
Also in the site preparation phase is the recycling facility at Redwood's planned battery materials campus in Ridgeville, South Carolina, which also is designed to produce 100 gigawatt-hours' worth of recoverable material per year. Subscribers can read more information on construction of the recycling and materials facilities in Ridgeville. Construction of the recycling facility is expected to wrap up around the end of 2026, and the materials facility a year later.
Redwood's Nevada project is the recipient of a $2 billion conditional loan commitment from the U.S. Department of Energy (DOE) through Inflation Reduction Act (IRA) funding. Although it remains to be seen whether President Donald Trump has an appetite for cutting IRA funding, the funds for this battery-recycling project and others like it may not be on the chopping block. Last month, the president issued an executive order invoking the Defense Production Act to promote U.S. production of critical minerals: "The Trump Administration will coordinate with private industry to ensure a stable and resilient domestic supply chain for critical materials, including critical minerals," according to a fact sheet.
Other battery-recycling projects underway include two grassroot efforts from Cirba Solutions (Charlotte, North Carolina), with engineering, procurement and construction (EPC) provider Jacobs Solutions Incorporated (NYSE:J) (Dallas, Texas): a 400,000-square-foot recycling-and-processing plant in Columbia, South Carolina is expected to recover material to power more than 500,000 EVs per year once construction wraps up later this year, while a recycling facility in Lancaster, Ohio is expected to process material for more than 250,000 EVs per year after construction wraps up in mid-2026. Subscribers can learn more by viewing the South Carolina and Ohio project reports.
Meanwhile, American Battery Technology Company (ABTC) (Reno, Nevada) expects a Phase 2 expansion of a pilot-scale lithium ion battery recycling plant in McCarran, Nevada will wrap up later this year, while a proposed Phase 3 phase would boost capacity to 100,000 tons per year. This facility demonstrates the ability to manufacture battery-grade lithium hydroxide from Nevada-based claystone material. Subscribers can read more on the Phase 2 and Phase 3 projects.
ABTC is doing its part to serve the need for recycled battery materials: The company recently announced it doubled production of recycled battery materials at its commercial-scale lithium-ion battery recycling facility in McCarran in the first quarter compared to fourth-quarter 2024. The company also is evaluating a second commercial-scale facility with approximately five times the throughput capacity of its first facility, although Industrial Info deems the project as having a low-probability of kicking off in September.
In December of last year, the company received a $144 million grant from the DOE to support the development and construction of the facility. Subscribers can click here to read more project information.
Subscribers to the GMI Database can click here for the reports on all of the projects discussed in this article and here for the plant profiles.
Click here for a full list of lithium-ion battery recycling projects in the U.S.
Industrial Info Resources (IIR) is the leading provider of industrial market intelligence. Since 1983, IIR has provided comprehensive research, news and analysis on the industrial process, manufacturing and energy related industries. IIR's Global Market Intelligence (GMI) helps companies identify and pursue trends across multiple markets with access to real, qualified and validated plant and project opportunities. Across the world, IIR is tracking over 200,000 current and future projects worth $17.8 Trillion (USD).
In general, after batteries are dissembled and shredded, the result is "black mass," which can contain high amounts of lithium, cobalt, manganese and nickel. These materials can be extracted from the black mass and reused for new batteries or other applications.
About half of the total investment value of lithium-ion battery recycling projects in the U.S. is attributed to two projects underway from Redwood Materials Incorporated (Carson City, Nevada), to support the development of two circular battery recycling and material production campuses.
Redwood is at work expanding its campus in Carson City, where it operates the largest lithium-ion battery recycling facility outside of Asia. The expansion project entails constructing a 550,000-square-foot building and installing new equipment so the site can ultimately produce 35,000 metric tons per year of battery-grade copper foil and 100,000 metric tons per year of cathode active materials (CAM) using both new and recycled feedstocks. Site preparation is underway, and the project is expected to wrap up in 2028. Subscribers to Industrial lnfo's Global Market Intelligence (GMI) Metals & Minerals Project Database can click here to read the detailed project report.
Also in the site preparation phase is the recycling facility at Redwood's planned battery materials campus in Ridgeville, South Carolina, which also is designed to produce 100 gigawatt-hours' worth of recoverable material per year. Subscribers can read more information on construction of the recycling and materials facilities in Ridgeville. Construction of the recycling facility is expected to wrap up around the end of 2026, and the materials facility a year later.
Redwood's Nevada project is the recipient of a $2 billion conditional loan commitment from the U.S. Department of Energy (DOE) through Inflation Reduction Act (IRA) funding. Although it remains to be seen whether President Donald Trump has an appetite for cutting IRA funding, the funds for this battery-recycling project and others like it may not be on the chopping block. Last month, the president issued an executive order invoking the Defense Production Act to promote U.S. production of critical minerals: "The Trump Administration will coordinate with private industry to ensure a stable and resilient domestic supply chain for critical materials, including critical minerals," according to a fact sheet.
Other battery-recycling projects underway include two grassroot efforts from Cirba Solutions (Charlotte, North Carolina), with engineering, procurement and construction (EPC) provider Jacobs Solutions Incorporated (NYSE:J) (Dallas, Texas): a 400,000-square-foot recycling-and-processing plant in Columbia, South Carolina is expected to recover material to power more than 500,000 EVs per year once construction wraps up later this year, while a recycling facility in Lancaster, Ohio is expected to process material for more than 250,000 EVs per year after construction wraps up in mid-2026. Subscribers can learn more by viewing the South Carolina and Ohio project reports.
Meanwhile, American Battery Technology Company (ABTC) (Reno, Nevada) expects a Phase 2 expansion of a pilot-scale lithium ion battery recycling plant in McCarran, Nevada will wrap up later this year, while a proposed Phase 3 phase would boost capacity to 100,000 tons per year. This facility demonstrates the ability to manufacture battery-grade lithium hydroxide from Nevada-based claystone material. Subscribers can read more on the Phase 2 and Phase 3 projects.
ABTC is doing its part to serve the need for recycled battery materials: The company recently announced it doubled production of recycled battery materials at its commercial-scale lithium-ion battery recycling facility in McCarran in the first quarter compared to fourth-quarter 2024. The company also is evaluating a second commercial-scale facility with approximately five times the throughput capacity of its first facility, although Industrial Info deems the project as having a low-probability of kicking off in September.
In December of last year, the company received a $144 million grant from the DOE to support the development and construction of the facility. Subscribers can click here to read more project information.
Subscribers to the GMI Database can click here for the reports on all of the projects discussed in this article and here for the plant profiles.
Click here for a full list of lithium-ion battery recycling projects in the U.S.
Industrial Info Resources (IIR) is the leading provider of industrial market intelligence. Since 1983, IIR has provided comprehensive research, news and analysis on the industrial process, manufacturing and energy related industries. IIR's Global Market Intelligence (GMI) helps companies identify and pursue trends across multiple markets with access to real, qualified and validated plant and project opportunities. Across the world, IIR is tracking over 200,000 current and future projects worth $17.8 Trillion (USD).
