At some point we need to Recycle batteries. This can be approached in many different ways and even could result in going back to the raw materials.
Why Recycling Matters
Battery recycling sits at the intersection of three converging pressures: a looming wave of end-of-life material, a structurally constrained primary supply chain, and a regulatory framework that is moving from voluntary to mandatory. Each of these alone would justify investment in recycling infrastructure. Together, they are driving one of the fastest-growing sectors in the battery industry.
Cell Production
In cell production there is a need to recycle materials at all stages of the process. At first this might appear strange, but electrodes are coated and then cut to size. This is all part of producing at scale and at a low cost, but does mean that active materials need to be removed from electrodes and processed to recover them.
Battery Recycling: A Need of the hour
Lithium Ion Batteries of today use raw materials such as Lithium, Cobalt, Nickel, Copper, Manganese, Graphite, Aluminum. Some of them are classified as Critically rare according to a EU study.
State of Battery Recycling: Can we meet our LIB recycling obligations by 2030?
In the European Union, the EU Battery Regulation (EU) 2023/1542 is now in force and classifies electric vehicle batteries with dedicated carbon footprint and recycling obligations. Minimum recycling efficiency for lithium-based batteries rises from 65% (December 2025) to 70% (December 2030); separate materials-recovery targets phase in later, reaching lithium 80% and nickel, cobalt and copper 95% by December 2031.
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Electric Vehicles Forecasting – Part 1
In order that we can understand the scale of battery recycling requirements we must first understand the size of the vehicle fleet.
There are lots of battery recycling companies: Recycling Companies
Key Minerals in a Battery
Pulling together an estimate of the key minerals in a battery so that we can use this within the Battery Pack Database. That would then allow us to offer a key set of numbers for battery recycling.
Dismantling
Battery Energy Storage System (BESS) Decommissioning
BESS decommissioning often involves unexpected challenges, equipment failures (e.g., pneumatic bander) or the need for improvised solutions (e.g., using a car inverter to charge power tools). Having a backup plan for every step of the process is essential.
4R’s Repair, Reman, Repurpose, Recycle
Before moving to the recycling of a battery the following options should be considered:
- Repair
- Remanufacture
- Repurpose
- Recycling
This approach can reduce cost, impact on the customer and most importantly the impact on the planet.
Batteries are not emissions and toxic waste free and so the life cycle analysis (LCA) must be considered from cradle to grave.
See also: Urban Mining: The Richest Ore Deposit You’ve Ever Thrown in a Drawer, Battery Passport
Related: For the pyro/hydro/direct trade-offs and how cell chemistry sets end-of-life value, see Recycling Process Engineering.