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Bosch Rexroth Announces 99% EV Battery Recycling Breakthrough

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  Published in Automotive and Transportation on Thursday, December 18th 2025 at 21:27 GMT by Channel NewsAsia Singapore

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Bosch Rexroth’s New EV‑Battery Recycling Breakthrough Signals a Turning Point for the Circular Economy

In a bold move that could reshape the electric‑vehicle (EV) supply chain, Bosch Rexroth, a leading global supplier of industrial automation and mobility solutions, announced a breakthrough in recycling EV batteries that promises to recover almost all the valuable metals from spent cells. The technology, unveiled in an advertorial on Channel NewsAsia, claims a 99‑percent recovery rate for lithium, nickel, cobalt, and other critical materials – a dramatic leap forward from the current 70‑plus percent recovery levels typical of most commercial recycling plants.

Why Battery Recycling Matters

The EV boom has spurred a surge in demand for lithium‑ion batteries, prompting governments and industry bodies worldwide to push for more sustainable end‑of‑life solutions. Beyond the obvious environmental benefit of reducing the carbon and water footprints associated with mining new metals, efficient recycling safeguards supply chains against price volatility and geopolitical risk. The EU’s Battery Regulation, effective from 2023, now requires battery producers to ensure that at least 55 % of battery materials come from recycled sources by 2030 – a target that will be difficult to hit without breakthroughs such as the one described by Bosch Rexroth.

The company’s advertorial references the broader circular‑economy agenda, noting that a closed‑loop battery system would cut down raw‑material extraction by up to 70 %. By re‑introducing the same metals into new cells, manufacturers can drastically lower their environmental footprints while also stabilizing costs.

The Core of the Technology

Bosch Rexroth’s proprietary process hinges on a combination of mechanical pre‑treatment and a controlled thermal‑chemical cycle. First, the battery pack is mechanically stripped of plastic and other non‑metallic components. The cells are then subjected to a precisely‑calibrated pyrolysis step at temperatures between 500 °C and 800 °C under a nitrogen atmosphere, which breaks down the organic binders without damaging the metallic electrodes.

What sets this process apart is the subsequent “hydrogen‑rich gas stream” that is introduced into the pyrolysis chamber. This stream acts both as a reducing agent and as a protective shield that prevents oxidation of critical metals such as nickel and cobalt. The result is a clean, metallurgically pure residue that can be smelted into high‑grade raw materials ready for reuse in new battery production.

The process is reported to recover 99 % of the metals in a spent cell, including lithium (up to 4 % of the cell weight), nickel (around 30 %), cobalt (about 12 %), manganese (roughly 7 %) and aluminium (5 %). The remaining 1 % is mainly trapped in the polymeric binder or in trace amounts of cathode materials that are notoriously difficult to isolate.

Pilot Plant and Partnerships

In collaboration with a leading battery manufacturer, Bosch Rexroth has set up a pilot plant in its German research facility that is now handling over 200 kg of used battery cells per week. The company claims that the scale‑up to a commercial plant – which could process 5 tonnes of battery waste per month – is well within reach, provided that sufficient supply of end‑of‑life batteries is secured.

The advertorial cites an upcoming partnership with a major German automaker that will channel the automaker’s used battery packs into the Rexroth plant. The automaker’s own circular‑economy initiatives, including a battery leasing model, dovetail neatly with Rexroth’s technology. This partnership will also help the automaker meet the EU’s 2030 recycling target without having to set up its own recycling infrastructure.

Environmental and Economic Pay‑offs

Using the Rexroth recycling process, the company estimates that the environmental impact of an average battery pack could be cut by up to 80 % in terms of CO₂ emissions. The technology also reduces the water consumption that is typical of hydrometallurgical recycling methods, which often require large volumes of electrolytes.

From an economic perspective, the recovered metals could be sold at a premium due to the rising global demand for EV batteries. Bosch Rexroth predicts a break‑even point after about 18 months of commercial operation, with the potential to generate significant revenue streams for battery producers and downstream recycling facilities.

Challenges Ahead

While the reported recovery rate is impressive, the advertorial acknowledges several hurdles that remain. First, the technology requires a steady flow of used batteries of a consistent chemistry – a condition that can be hard to guarantee given the proliferation of battery chemistries in the market. Second, the capital cost of setting up a full‑scale plant, especially the high‑temperature pyrolysis equipment, is non‑trivial. Finally, the environmental credentials of the process are only as good as the energy mix used to power it; Bosch Rexroth is therefore advocating for the integration of renewable energy sources in future plants.

The Bigger Picture

The Bosch Rexroth breakthrough is part of a larger wave of innovations that aim to transform the battery sector from a linear “take‑make‑dispose” model to a circular one. Industry analysts linked the development to other pioneering efforts in Europe, such as the “Batteries 4 Future” consortium, which is exploring alternative chemistries that are easier to recycle.

If the technology can be proven at scale, it could dramatically reduce the demand for newly mined lithium and cobalt – minerals that are currently sourced from a handful of politically unstable regions. It could also make the EU’s battery regulatory targets achievable without forcing manufacturers to resort to less sustainable, higher‑cost supply chain options.

Conclusion

Bosch Rexroth’s 99‑percent recycling claim is more than a headline; it is a tangible step toward a truly circular battery economy. By turning end‑of‑life cells into near‑pristine raw materials, the company not only offers an environmentally responsible solution but also a financially attractive one for battery producers and automakers alike. As the world edges toward a zero‑emission future, breakthroughs such as this will be critical in ensuring that the supply chain is both sustainable and resilient.