High-Volume Battery Recycling: Technical Review of Challenges and Future Directions

The growing demand for lithium-ion batteries (LIBs), driven by their use in portable electronics and electric vehicles (EVs), has led to an increasing volume of spent batteries. Effective end-of-life (EoL) management is crucial to mitigate environmental risks and prevent depletion of valuable raw materials like lithium (Li), cobalt (Co), nickel (Ni) and manganese (Mn). Sustainable, high-volume recycling and material recovery are key to establishing a circular economy in the battery industry. This paper investigates challenges and proposes innovative solutions for high-volume LIB recycling, focusing on automation for large-scale recycling. Key issues include managing variations in battery design, chemistry, and topology, as well as the availability of sustainable raw materials and low-carbon energy sources for the recycling process. The paper presents a comparative study of emerging recycling techniques, including EV battery sorting, dismantling, discharge, and material recovery. With the expected growth in battery volume by 2030 (1.4 million per year by 2040), automation will be essential for efficient waste processing. Understanding the underlying processes in battery recycling is crucial for enabling safe and effective recycling methods. Finally, the paper emphasizes the importance of sustainable LIB recycling in supporting the circular economy. Our proposals aim to overcome these challenges by advancing automation and improving material recovery techniques.