Imagine it’s 2030, when electric vehicles (EVs) dominate the roads and drones dominate the sky, providing an eco-friendly transport alternative. The integration of cutting-edge technologies like AI has made smartphones smarter than ever. Most homes are powered by renewable energy sources, harnessing the sun and wind to create a sustainable future.
But there’s a catch.
Lurking beneath this remarkable imagined (soon become a reality) green revolution is a troubling reality. A vast mountain of used batteries in electric vehicles, drones, smartphones, laptops, etc. pose a significant environmental threat. While these batteries are essential for powering modern conveniences, they raise an urgent question about their timely disposal and the long-term impact on our planet.
In this post, we will discuss the importance of battery recycling, various recycling processes, and key market movers in battery recycling.
Battery recycling is crucial for conserving valuable resources like lithium, cobalt, and nickel, which are limited and found in every lithium-ion battery. Recycling helps reduce the need for mining and lowers energy consumption. It also prevents toxic chemicals from leaking into the environment, protecting soil and water from contamination. By recycling batteries, we promote a circular economy, reduce pollution, and decrease the carbon footprint of production and disposal.
Did you know that mining a ton of cobalt emits as much CO₂ as driving a car for six months? Recycling can reduce this impact dramatically, recovering up to 95% of critical materials while cutting emissions.
As the demand for lithium-ion batteries continues to rise, particularly with the proliferation of electric vehicles (EVs), innovative recycling methodologies are becoming increasingly crucial. Here are some of the latest advancements in battery recycling techniques:
Solvent-Free Flash Joule Heating (FJH): Developed by researchers at Rice University, this method involves rapidly heating battery waste to 2,500 Kelvin using a current passed through a moderately resistive material. This technique facilitates the creation of unique magnetic properties in cobalt-based battery cathodes allowing for efficient separation and purification of valuable materials. The process boasts a remarkable recovery yield of 98% while maintaining the structure and functionality of the materials making it highly effective for recycling lithium-ion batteries.
Direct Recycling Using Eutectic Mixtures: A novel technique involves using a eutectic combination of lithium iodide (LiI) and lithium hydroxide (LiOH) that melts at lower temperatures (under 200°C). This method allows for the repair and restoration of lithium-ion battery cathodes while consuming less energy compared to traditional methods. The two-step heating process can restore materials to full functionality, providing a cost-effective alternative to producing new battery components.
Battery Recycling and Water Splitting (BRAWS) Technology: Developed by scientists at the U.S. Department of Energy Ames National Laboratory, this innovative process utilizes only water and carbon dioxide to recycle lithium-ion batteries. After dismantling the battery, the anode is immersed in water, and CO2 is added to recover lithium as lithium carbonate. This method not only recovers almost all lithium but also produces green hydrogen as a byproduct, making it an environmentally friendly alternative to conventional methods that rely on chemicals and high heat.
Hydrometallurgical Processing: Hydrometallurgical processing of lithium-ion batteries is an environmentally friendly method that utilizes aqueous solutions to extract valuable metals from spent batteries. The process begins with the pretreatment phase, where discharged batteries are dismantled and shredded to create a “black mass” containing the active materials. This black mass is then subjected to leaching, where it is treated with acidic or alkaline solutions, such as sulfuric acid, which dissolve metals like lithium, cobalt, nickel, and manganese into the solution. Following leaching, various separation techniques, including solvent extraction and precipitation, are employed to recover the dissolved metals, ensuring high purity for reuse.
Pyrometallurgical Processing of Lithium-Ion Batteries: Pyrometallurgy begins with the pretreatment of spent batteries, which involves discharging, dismantling, and shredding them to produce a “black mass” containing the active materials. This black mass is then subjected to high-temperature smelting, typically between 1200°C and 1600°C. During this phase, organic materials combust, and the metals are oxidized and melted, allowing for the separation of metal oxides from impurities. The resulting products include a metal alloy containing recoverable metals and a slag that contains non-recyclable materials.
Headquartered in Baar, Switzerland, the company has been actively collaborating with ACE Green Recycling, Li-Cycle, and others to recycle both lead-acid and lithium-ion batteries.
Glencore is collaborating with Li-Cycle to develop Europe’s largest battery recycling plant at the Portovesme Hub in Italy. The recycling plant is expected to be operational by late 2026 or early 2027 and will be the largest producer of recycling battery-grade lithium in Europe.
Further, the company aims to set up additional facilities in Spain and Portugal alongside FCC Ámbito and Iberdrola.
Stena Recycling, in collaboration with EV HUB, uses an AI algorithm to assess the battery’s condition. Thus enabling the potential reuse of batteries that otherwise might be scrapped and improving the efficiency of the recycling process. Additionally, the company’s partnership with BASF focuses on collecting end-of-life batteries, pre-treating them, and producing black mass for further processing to recover critical metals.
The recycling center in Halmstad is one of Europe’s largest and most modern recycling facilities. Further, the company has been constructing a new dedicated EV battery recycling plant is being constructed at the Ausenfjellet site in.
Headquartered in Jiangxi Province, China, the company primarily employs two recycling technologies – Waste Lithium Iron Phosphate Battery Recycling and Waste Ternary Battery Recycling. These technologies allow Ganfeng to efficiently recover valuable materials while minimizing environmental impact. The company operates several recycling facilities in China and Mexico.
Li-Cycle Holdings Corp. employs innovative battery recycling technology through its Spoke and Hub Technologies™, which are designed to recycle lithium-ion batteries (LIBs) efficiently and sustainably. The company operates several recycling facilities in North America ( New York, Arizona, Alabama, and Ohio) and Europe (Sülzetal, Germany).
Now imagine this: Every EV battery you use today becomes the building block for the next generation. No waste. No new mining.
Just a continuous cycle of energy powering the future. This vision isn’t far-fetched—it’s achievable with collaboration among innovators, regulators, and consumers. Battery recycling isn’t just a solution; it’s a necessity for the planet and our progress. The batteries of tomorrow don’t just store energy—they promise a cleaner, more sustainable world. It’s up to all of us to make that promise a reality.
Keep yourself updated with the latest technology and emerging solutions in the battery recycling sector. We offer an exhaustive overview of new startups, scale-ups, emerging technologies, and much more that are shaping the future of battery recycling. Contact our subject matter experts and don’t miss out on the opportunity to position yourself at the forefront of innovation.
