Pioneering Sustainable Battery Recycling and Manufacturing

During the development of plans for a new brownfield manufacturing facility, Ascend Elements engaged SSOE to provide engineering and design services. The focus was on renovating an existing 150,000 SF industrial building, which they had leased and equipped for recycling lithium ion batteries. The project unfolded through several key phases: front-end loading (FEL 2 and 3), detailed design, procurement, construction, and commissioning.

As a start-up, Ascend Elements faced the challenge of designing each production line component to achieve their ultimate goal: producing “black mass.” This valuable powder contains critical materials like nickel, cobalt, lithium, and graphite. SSOE played a pivotal role in refining Ascend Elements’ patented Hydro-to-Cathode™ process, which drastically reduces the carbon footprint of new battery cathode materials by up to 90%. The process involves discharging scrap batteries fully, crushing battery cases, and providing efficient dust collection. The recycling plant achieves an impressive 98% recovery rate for critical battery metals used in electric vehicle (EV) batteries and gigafactory manufacturing scrap. By contributing to a closed-loop battery materials supply chain, Ascend Elements supports a cleaner and more sustainable EV industry.

Beyond the initial ribbon-cutting and production start-up, Ascend Elements continued to leverage SSOE’s expertise. Together, we optimized and debottlenecked their cutting-edge process, implementing new unit operations within the production factory. SSOE’s understanding of day-today manufacturing criticality facilitated seamless integration of process improvements.

Today, SSOE remains a trusted project delivery partner for Ascend Elements. Our collaboration extends to designing a state-of-the-art, first-of-its-kind EV battery materials manufacturing facility in Hopkinsville, Kentucky. Situated on a sprawling 140-acre megasite, this complex includes over 800,000 SF of manufacturing space, reinforcing Ascend Elements’ commitment to innovation and sustainability.