Battery Lifecycle and Recycling Technologies Shape EV Future

Regulatory Pressure from Europe Expands Scope

The European Union is preparing to enforce the new Battery Regulation in 2025, requiring manufacturers to design battery systems with recyclability in mind. Among the key provisions is a phased target for lithium-ion cells to achieve a minimum 70% recovery rate. Countries such as Germany, France, and Spain have already formed working groups to align national policies with this regulation. Simultaneously, Turkey's Ministry of Environment, Urbanization and Climate Change is working on harmonization, emphasizing that local producers will gain a competitive edge through enforced recycling contributions.

Lifespan Extension: From Cell Chemistry to Software

In the race to enhance battery durability, reducing cobalt in cathode materials has become a primary focus. Companies like Tesla and BYD report reaching up to 4,000 charge cycles by lowering cobalt levels in nickel-manganese-cobalt (NMC) chemistries. Meanwhile, Ford and Stellantis are exploring lithium-sulfur electrolytes in solid-state battery prototypes for improved thermal stability. Local startup BATTECH is focusing on thermal regulation technologies. According to its co-founder Dr. Selin Arslan, maintaining battery temperatures within a ±2 °C range can increase lifespan by up to 15%.

Recycling Ecosystem Gains Momentum

Instead of heading directly to metal recovery plants, many decommissioned batteries are now evaluated for second-life use. Companies like Li-Cycle and Northvolt claim to achieve over 90% purity in recovered nickel and lithium through mechanical-hydrometallurgical processes. In Gebze Organized Industrial Zone, the RecycleTR facility is preparing to launch with an annual processing capacity of 20,000 tons. Experts note that recent fluctuations in lithium carbonate prices have made recycled raw materials a more stable option for manufacturers.

Second-Life Applications: Energy Storage Takes the Lead

Batteries falling below 80% capacity are increasingly being repurposed for residential and grid-scale energy storage. UK-based Connected Energy converts old electric bus batteries into 15 MWh containerized units to help data centers manage peak load demand. In Turkey, a collaboration between Enerjisa and Aselsan aims to integrate retired EV batteries into microgrid solutions. The Ministry of Energy and Natural Resources is expected to announce new incentive tariffs supporting second-life applications by year-end.

Domestic Manufacturing and Strategic Alignment

TOGG, based in Bursa, is set to open its battery module plant in 2026, focusing on modular and easily dismantlable designs. The company is also developing a protocol for transmitting real-time cell health data to a brand-independent cloud platform. Nearby, Farasis Energy Europe has expanded its cobalt-free cathode production line, potentially reducing toxic waste in recycling processes by up to 30%.

Expert Insight: Circular Model Offers Resilience

According to Prof. Dr. Levent Akın, Director of the Sustainable Energy Center at Boğaziçi University, blockchain-based digital passports for batteries enhance traceability and significantly reduce recycling costs. He emphasizes that manufacturers adopting circular models will be more resilient to raw material price volatility and will align more effectively with global supply chain expectations.

As advancements in battery chemistry, strict regulations, and emerging recycling technologies converge, the electric vehicle industry is evolving from linear production toward sustainable resource management. The steps taken in Turkey not only support local integration into global markets but also create a foundation for responsible environmental practices.