Rivian Second-Life Battery Storage Project Links EV Packs to Grid Reliability

Rivian, Redwood

Rivian second-life battery storage is moving into commercial use after the US electric-vehicle maker agreed to deploy repurposed battery packs through Redwood Materials at its Normal manufacturing plant in Illinois. The project will use more than 100 used Rivian battery packs to provide 10 MWh of dispatchable battery energy storage.

The Rivian second-life battery storage project gives retired EV packs a second use before recycling. Redwood Materials will integrate the packs into a Redwood Energy system for on-site use at Rivian’s manufacturing facility.

Rivian second-life battery storage also reflects a wider shift in the battery value chain. Automakers and recyclers are looking for ways to extract more value from battery packs before recovering lithium, nickel, cobalt, copper, aluminium and other materials.

Redwood Turns Used EV Packs Into Stationary Storage

Redwood will receive EV battery packs from Rivian and convert them into a battery energy storage system for the Normal plant. The system will help reduce energy costs and support local grid reliability.

Second-life batteries are useful because EV packs can still retain meaningful capacity after vehicle use. They may no longer meet automotive performance requirements, but they can still serve stationary storage applications.

This creates a bridge between mobility and grid infrastructure. A battery pack can first support vehicle electrification, then provide stationary power, and later enter recycling for critical material recovery.

Redwood receives more than 20 GWh/yr of batteries, giving it a large feedstock base for both reuse and recycling. The company said it can deploy BESS projects in as little as six months, which matters as power demand rises quickly.

Data Center Power Demand Raises Storage Value

Rivian has attracted investors such as Google, which are seeking faster access to power solutions for artificial intelligence data center growth. This connection shows why second-life batteries are becoming more strategically relevant.

AI data centers need reliable, flexible and rapidly deployable power. Battery energy storage systems can help manage peak demand, improve resilience and reduce pressure on grids facing new large-load connections.

Repurposed EV batteries could become a lower-cost option where speed matters more than maximum energy density. They may also reduce waste and delay the need for immediate material recycling.

For the metals supply chain, this creates a more circular model. Battery materials stay in productive use longer, while recyclers build stronger long-term access to end-of-life packs and future recovered metals.

The Metalnomist Commentary

Rivian and Redwood are showing how EV batteries can become grid assets before they become recycling feedstock. The strategic value lies in extending battery life, lowering storage costs and securing future material recovery in one integrated loop.

BMW Partners with Redwood to Recycle Lithium-Ion Batteries

Redwood

BMW Group has entered into a partnership with US-based battery recycler Redwood Materials to recycle lithium-ion batteries from electric vehicles (EVs) in the automaker's portfolio. Under the deal, announced Monday, Redwood will gain access to over 700 BMW Group locations across the United States, including dealerships, distribution centers, and internal facilities, to source end-of-life batteries.

Expanding Battery Recycling Operations

Redwood highlighted its proximity to BMW's Spartanburg and Woodruff manufacturing plants in South Carolina, where one of its two campuses is located. Both companies are committed to establishing significant recycling operations in the area. BMW has aggressive plans to produce at least six electric vehicle models in the US by 2030, with a $1 billion investment to retrofit its Spartanburg plant to produce electric SUVs by 2026. Additionally, the nearby Woodruff facility will support Spartanburg by supplying batteries from its new $700 million battery assembly plant, expected to be operational by 2026.

This collaboration with BMW adds to Redwood's growing network of partnerships with automakers and battery manufacturers. In May, Redwood entered a deal with Ultium, a joint venture between General Motors and LG Chem, to recycle production waste from two facilities, which are expected to generate 10,000 metric tonnes of cathode and anode scrap annually.

Cyclic Lime Rare Earth Recycling Partnership Targets Electric Scooter Motor Magnets

Cyclic Materials

Cyclic Lime rare earth recycling partnership launched as Canadian recycler Cyclic Materials contracted with electric scooter company Lime to recover rare earth elements from decommissioned motors. The Cyclic Lime rare earth recycling collaboration will process magnets from Lime's retired electric bike and scooter fleet across US and Canadian operations, establishing a circular economy model for critical materials recovery from urban mobility infrastructure.

Hydrometallurgical Processing Creates Closed-Loop Supply Chain

Cyclic Lime rare earth recycling operations will utilize Cyclic's dual-facility processing network spanning Mesa, Arizona, and Kingston, Ontario. The Kingston facility employs hydrometallurgical processes to produce mixed rare earth oxide from recovered magnet materials. Mesa represents Cyclic's first US processing location, expanding the company's geographic reach for North American rare earth recycling operations.

Meanwhile, the partnership targets Lime's substantial fleet of over 270,000 electric bikes and scooters operating across 280 cities globally. This scale provides consistent feedstock volumes for rare earth recovery operations while addressing end-of-life disposal challenges for electric mobility devices. The collaboration demonstrates practical applications of circular economy principles in urban transportation sectors.

Scaling Operations Address Growing E-Mobility Waste Streams

However, Cyclic and Lime plan operational commencement within weeks, with activity scaling throughout 2025 as fleet retirement cycles mature. The timing aligns with growing volumes of first-generation electric scooters and bikes reaching end-of-life status after several years of intensive urban deployment. This natural replacement cycle creates predictable feedstock availability for recycling operations.

Therefore, the partnership addresses critical material recovery from permanent magnets containing neodymium, praseodymium, and dysprosium essential for motor performance. These rare earth elements maintain high value and strategic importance for electric vehicle and renewable energy applications. Recovery operations reduce dependence on primary mining while supporting domestic rare earth supply chain resilience.

Urban Mobility Recycling Model Demonstrates Industry Leadership

Furthermore, Lime's commitment to rare earth recycling complements existing battery recycling partnerships with companies like Redwood Materials. This comprehensive approach to component recycling establishes industry best practices for sustainable electric mobility operations. The integrated recycling strategy addresses both battery and motor component end-of-life management across Lime's global fleet.

As a result, the Cyclic partnership positions Lime as a leader in sustainable urban mobility practices while creating valuable secondary rare earth supply sources. The collaboration demonstrates how service-based mobility companies can contribute to critical materials circularity while managing operational costs through material recovery value. This model could influence broader electric vehicle and mobility industry recycling practices.

The Metalnomist Commentary

The Cyclic-Lime partnership represents an innovative approach to rare earth recycling that leverages the predictable replacement cycles of commercial electric mobility fleets to create sustainable feedstock streams for critical materials recovery. This collaboration demonstrates how urban mobility companies can transition from being solely consumers of critical materials to active participants in circular supply chains, potentially serving as a model for broader transportation electrification sectors.

Toyota Secures $4.5 Million DOE Funding for EV Battery Recycling Technology

Argonne National Laboratory

Toyota, a global leader in automotive innovation, has received $4.5 million from the US Department of Energy (DOE) to advance cutting-edge electric vehicle (EV) battery recycling technology. This initiative aims to address critical bottlenecks in battery recycling, including automating pack disassembly, improving battery identification and sorting with data-driven methods, and mitigating challenges posed by cell degradation.

The Toyota Research Institute of North America will spearhead this project by developing autonomous robotic systems to disassemble EV batteries, an essential step toward enhancing sustainability and efficiency in the battery supply chain.

Efforts to Build a Sustainable Battery Ecosystem

As the demand for EVs grows, so does the volume of spent batteries and manufacturing scrap. Toyota’s initiative represents an effort to make the recycling process more sustainable, efficient, and scalable.

This latest project builds on Toyota’s growing portfolio of collaborations and research in battery recycling:

• April 2024: Partnered with Argonne National Laboratory to explore direct recycling processes for cathode chemistries containing critical minerals like nickel, manganese, and cobalt.

• Late 2023: Partnered with Cirba Solutions to enhance the collection, storage, testing, and recycling of spent batteries.

• 2022: Collaborated with Redwood Materials to focus on recycling hybrid EV batteries through improved collection and testing methods.

By working with leading recycling companies and research organizations, Toyota aims to ensure that its batteries are part of a closed-loop supply chain, reducing reliance on virgin materials and enhancing the sustainability of its EV production process.

The Path Ahead for EV Sustainability

This DOE-funded project underscores the increasing importance of a sustainable battery supply chain as EV adoption rises globally. By tackling technical challenges such as cell degradation and automation, Toyota is paving the way for scalable recycling solutions critical to the EV industry’s future.