Mdpi Research Paper
Mdpi Research Paper
Mdpi Research Paper
Review
Special Issue
Recycling of Lithium Ion Batteries and Other Next Generation Materials
Edited by
Dr. Sascha Nowak
https://doi.org/10.3390/recycling7030033
recycling
Review
Lithium-Ion Battery Recycling in the Circular Economy:
A Review
Md Tasbirul Islam * and Usha Iyer-Raniga
School of Property Construction and Project Management, RMIT University, 360 Swanston Street,
Melbourne, VIC 3000, Australia; usha.iyer-raniga@rmit.edu.au
* Correspondence: md.tasbirul.islam@rmit.edu.au
Abstract: Lithium-ion batteries have become a crucial part of the energy supply chain for transporta-
tion (in electric vehicles) and renewable energy storage systems. Recycling is considered one of the
most effective ways for recovering the materials for spent LIB streams and circulating the material in
the critical supply chain. However, few review articles have been published in the research domain
of recycling and the circular economy, with most mainly focusing on either recycling methods or
the challenges and opportunities in the circular economy for spent LIBs. This paper reviewed 93
articles (66 original research articles and 27 review articles) identified in the Web of Science core
collection database. The study showed that publications in the area are increasing exponentially,
with many focusing on recycling and recovery-related issues; policy and regulatory affairs received
less attention than recycling. Most of the studies were experiments followed by evaluation and
planning (as per the categorization made). Pre-treatment processes were widely discussed, which
is a critical part of hydrometallurgy and direct physical recycling (DPR). DPR is a promising recy-
cling technique that requires further attention. Some of the issues that require further consideration
include a techno-economic assessment of the recycling process, safe reverse logistics, a global EV
assessment revealing material recovery potential, and a lifecycle assessment of experiments processes
(both in the hydrometallurgical and pyrometallurgical processes). Furthermore, the application of
the circular business model and associated stakeholders’ engagement, clear and definitive policy
Citation: Islam, M.T.; Iyer-Raniga, U.
Lithium-Ion Battery Recycling in the
guidelines, extended producer responsibility implications, and material tracking, and identification
Circular Economy: A Review. deserve further focus. This study presents several future research directions that would be useful
Recycling 2022, 7, 33. for academics and policymakers taking necessary steps such as product design, integrated recycling
https://doi.org/10.3390/ techniques, intra-industry stakeholder cooperation, business model development, techno-economic
recycling7030033 analysis, and others towards achieving a circular economy in the LIB value chain.
Academic Editor: Sascha Nowak
Keywords: circular business model; policy; 2nd life application; remanufacturing; reverse logistics;
Received: 30 April 2022 lifecycle assessment (LCA)
Accepted: 26 May 2022
Published: 28 May 2022
focus on supporting social and environmental goals [5]. Coupled with resource circula-
tion, the decarbonization of the economy also created significant momentum, especially
in the transport and mobility sector [6], which is one of the critical contributors to global
CO2 emissions. Electric vehicles (EV) are one of the greatest innovations contributing
to a positive environmental performance, apart from the source of electricity generation
being ignored (i.e., coal power electricity has negative impacts on the ecosystem). The
production of EVs requires a large battery pack to be manufactured as well. For exam-
ple, a lithium-ion battery pack, considering the currently available technology used in
Tesla EVs and others that contain various critical cathode materials, such as CO, Ni, and
Li, has low resource stock and anode materials, such as Al, Cu, and graphite. Due to
the high energy and power densities, lithium-ion batteries (LIBs) are widely used in the
battery storage system in electric vehicles [7] as well as in the renewable energy supply
system, such as solar PV [8]. Furthermore, in significant components and small electronic
equipment (e.g., mobile phones, handheld power tools, and others), the application of
LIBs is widespread [9]. According to their chemistries, batteries are generally categorized
as lithium-ion batteries (LIBs), lead-acid (PbA) batteries, nickel-metal hydride (NiMH)
batteries, and nickel-cadmium (NiCd) [10]. Excluding two- and three-wheeler vehicles, as
of 2019, the current global electric vehicle stock reached 7 million, which is expected to
reach 140 million by 2030, thereby accounting for 7% of the total vehicle fleet [11]. With the
greater penetration of electric batteries, the demand for LIB production will continue to in-
crease [12]. From a product lifecycle perspective, LIBs are one of the most material intensive
product stocks that must be taken care of at any stage of their lifespan. End-of-life (EoL)
treatment from various waste streams (in CE, they are resources) created unprecedented
challenges in all sustainability indicators and pillars. Recycling as the end of pipe solution
is one of the ways of circulating the materials; however, heterogeneity in product design
and various battery chemistries created crucial barriers to this path. On the other hand, no
specific guidelines have been developed for the utilization of the remaining life of LIBs for
other purposes, along with the technical reliability of using it in secondhand applications.
Aggregately, these phenomena are creating severe environmental challenges both on the
supply side and on the demand side. As mentioned earlier, the battery contains various
rare-earth elements and metals that can address current mineral shortages but can contami-
nate material if not properly recycled. For example, in 2019 from Australia and Chile, 55%
and 24%, respectively, were extracted, and Co, one of the significant components of LIBs,
can only be found in conflict zones, such as the Democratic Republic of Congo where 70%
of the Co originated in the same year [13]. If appropriate disposition alternatives such as
recycling, reusing, and remanufacturing are not collected and selected in an optimized
manner, targets and progress towards achieving net-zero emissions from the transportation
sector and climate change mitigation would critically underperform. A traditional linear
economy (take-make-throw) is not applicable, as some of the high-value material cycles
must be closed-looped to tackle risk in the global supply chain. On the other hand, the CE
creates opportunities for product manufacturers and businesses to utilize the resources at
their maximum level and minimize waste and pollution. Applications of circular business
models [14], the collaboration of all stakeholders [15], and data-driven decision support
systems [13] are required for appropriate planning to adhere to the CE principles for LIBs.
The alternatives mentioned above also indicate core CE strategies that holistically combine
the lifecycle and supply chain of the LIB value chain. Figure 1 shows the LIB value chain.
Recycling 2022, 7, x FOR PEER REVIEW 3 of 39
Recycling 2022, 7, 33 3 of 40
Figure
Figure1.
1.Value
Value chain
chain of
of LIBs,
LIBs, redrawn
redrawn from
from [16].
[16].
Therecycling
The recyclingtechniques
techniquesfor forLIBs
LIBsare arestill
stillunder
underdevelopment,
development,and andthere
thereisiscurrently
currently
no technology available (each technology has certain advantages
no technology available (each technology has certain advantages and disadvantages) that and disadvantages) that
would permit
would permit thetherecovery
recoveryofofallall elements
elements fromfrom used batteries.
used Furthermore,
batteries. Furthermore, therethere
are huge are
huge losses in the current technological innovation, and, at the same time, battery chem-is
losses in the current technological innovation, and, at the same time, battery chemistry
always
istry evolving.
is always Therefore,
evolving. recycling
Therefore, requires
recycling continuous
requires advancement
continuous advancementaccording to the
according
material use, battery system design, and manufacturing process.
to the material use, battery system design, and manufacturing process. This article focused This article focused on
LIB recycling and the circular economy and reviewed original
on LIB recycling and the circular economy and reviewed original research articles pub- research articles published in
peer-reviewed journals to explore the interdisciplinary connection among various research
lished in peer-reviewed journals to explore the interdisciplinary connection among vari-
dimensions. The Web of Science (WoS) core collection database is utilized for this study.
ous research dimensions. The Web of Science (WoS) core collection database is utilized
First, the keywords “recycling” and “circular economy” are searched as the topic with the
for this study. First, the keywords “recycling” and “circular economy” are searched as the
AND operator, which retrieved 3998 articles. Later, in the refined keyword search window,
topic with the AND operator, which retrieved 3998 articles. Later, in the refined keyword
the “lithium-ion batteries” OR “Li-ion batteries” keywords were utilized, which provided
search window, the “lithium-ion batteries” OR “Li-ion batteries” keywords were utilized,
123 articles, including both original articles (93 articles) and review articles (30 articles).
which provided 123 articles, including both original articles (93 articles) and review arti-
Out of 30 review articles, 27 are evaluated in Table 1, showing the core discussion areas
cles (30 articles). Out of 30 review articles, 27 are evaluated in Table 1, showing the core
in the previously published articles. The search was performed on 17 April 2022. Out of
discussion areas in the previously published articles. The search was performed on 17
93 articles, a total of 66 articles were selected for final review after screening. Including
April 2022. Out of 93 articles, a total of 66 articles were selected for final review after
the original and review articles, this review analyzed 93 articles. The criteria for choosing
screening. Including the original and review articles, this review analyzed 93 articles. The
the articles were: (1) the abstract, keywords, and title must contain the keywords circular
criteria
economy, forlithium-ion
choosing the articlesand
batteries, were: (1) the abstract,
recycling-related keywords,
topics; (2) if anyand title discussed
article must contain only
the keywords circular economy, lithium-ion batteries,
the topic of a circular economy but not recycling, they were excluded. Besides and recycling-related topics; (2) if
recycling
any
LIBs,article
as thediscussed only thewas
circular economy topic of included
also a circularineconomy
the keyword but not recycling,
strings, some of they
the were
other
excluded. Besides recycling LIBs, as the circular economy
associated subject areas emerged in the collection of the articles. Examples of thiswas also included in thearekey-
the
word
circularstrings,
economy some of the other
business model, associated subject areas emerged
reuse, remanufacturing, recovery,inpolicy,
the collection of the
and regulation.
articles. Examples
The difference of this
between are the and
recovery circular economy
recycling business
is that model,
the recovery reuse,mainly
process remanufactur-
involves
ing,
the pre-processing stages. The recycling process of LIBs is shown in Figure 2. recycling is
recovery, policy, and regulation. The difference between recovery and
that the recovery
This reviewprocess mainly
article aims involvessignificant
to identify the pre-processing
themes and stages. The recycling
research process
topics emerging
of LIBs is shown in Figure 2.
from the aspects of recycling and the issues related to a whole circular economy. It is to be
This review
understood article aims
that recycling to identify
is one of the mostsignificant themes
significant and research
pathways topics to
or strategies emerging
achieve
from the aspects
a circular economy. of recycling
However, andsomethe ofissues relatedarticles
the review to a whole circularoneconomy.
published spent LIBs It is to
only
be understood
focus on recycling thatprocesses,
recyclingwhile
is one of the
others focusmost on significant
second life pathways
applications or(i.e.,
strategies
assessing to
achieve a circular This
reuse potential). economy. However,
indicates a gap in some
the of the review
literature articles
showing published
from a holisticonperspective
spent LIBs
only focus on recycling
that including processes, while
a decision-support system others focus on second
and environmental life applications
assessment methods, (i.e.,such
as-
sessing reuse potential). This indicates a gap in the literature
as a lifecycle assessment, provide a comprehensive understanding of circular economy showing from a holistic per-
spective
prospectsthat for including
waste LIBs.a Therefore,
decision-supportthis reviewsystem andidentifies
article environmental
gaps in assessment
the literaturemeth- from
ods, such as a lifecycle
an interdisciplinary assessment,
perspective and provide
shows the a status
comprehensive
and futureunderstanding of circular
research opportunities for
economy
a circularprospects
economy for waste
as far LIBs.LIBs
as spent Therefore, this review article identifies gaps in the lit-
are concerned.
erature from an interdisciplinary perspective and shows the status and future research
opportunities for a circular economy as far as spent LIBs are concerned.
Recycling 2022, 7, 33 4 of 40
Table 1. Summary of the previously published review articles on recycling and circular economy.
Year of Country of
Reference Focus of the Study Major Findings
Publication Publication
1. Product design and green chemistry
for green recovery are critical to the
Reuse and recycling streamlined and automated recycling
Pagliaro and Meneguzzo [21] 2019 Italy perspective of circular process.
economy 2. Electric vehicles, renewable energy
systems, and battery storage systems will
be essential.
1. Pyrometallurgical recycling process is
robust; however, only metallic elements
can be recovered through the process.
Velázquez-Martínez, et al. [22] 2019 Finland LIBs recycling processes 2. In remanufacturing, focused- LIBs
material recovery activities, mechanical
processing, and hydro- and
pyrometallurgical processes are required.
1. Recycling processes in the future will
depend on battery cell design.
2. Besides green material recovery
Thompson, et al. [23] 2020 UK Design
techniques, the techno-economic analysis
should be performed to understand the
well-suited recycling process.
1. For closed-loop recycling of spent LIBs,
LIBs from e-waste bioleaching, waste for waste approach,
Roy, et al. [24] 2021 Singapore
recycling method and electrodeposition were identified as
crucial methods.
1. Recycling, reuse, and repurposing
should not be the only paths but rather
Potentials and barriers of implementing innovative business
Kautz, et al. [25] 2021 Germany circular economy in case models such as product as a service or
of waste LIBs sharing model. However, stakeholders
are in doubt about implementing such
business models.
1. Companies will be more inclined
toward a direct recycling method that
Challenges associated to depends on stabilizing battery
chemical composition, chemistries and enhanced electrolyte
Neumann, et al. [20] 2022 Germany recycling process and recovery capability.
approaches to battery 2. For solid-state batteries, mechanical
recycling handling and hydrometallurgy processes
would be more challenging to
implement.
1. Establishment of proper separation
technique and method should be applied
Material close-looping and
before recycling. Such arrangements
Doose, et al. [26] 2021 Germany challenges associated to
could be transnational.
battery recycling
2. For low-cost batteries, recycling is not
an attractive economic option.
1. Revenue generation after selling
secondary raw materials recovered from
spent batteries (including an efficient
collection scheme) is a decisive choice for
recycling.
Werner, et al. [27] 2020 Germany Recycling supply chain 2. In the long-run future recycling
capability should be expanded globally
to use the recoverable material in battery
manufacturing. However, present
demand will mainly rely on virgin
material production.
1. For a genuinely green battery
technology, from the policymakers’
Chemistries and recycling
Piatek,
˛ et al. [28] 2021 Sweden perspectives, sustainable recycling
methods of LIBs
concepts should be supported by EV
manufacturers.
Recycling 2022, 7, 33 5 of 40
Table 1. Cont.
Year of Country of
Reference Focus of the Study Major Findings
Publication Publication
1. Regulatory frameworks and
Pyrometallurgical
Makuza, et al. [29] 2021 China government incentives are the main
recycling process
drivers for innovation.
1. Hydrometallurgical process is less
intensive for the environment, and many
[30] 2022 Romania Recycling processes
of the current studies focus on these
recycling methods.
1. Pyrometallurgical process is mainly
used at an industrial scale; however, slag
formation and intense energy use often
restrict environmentally sound and
economically efficient lithium recovery,
calling for greener and more efficient
solutions.
2. Hydrometallurgical recycling is
Opportunities and
essentially cathode chemistry dependent
Mossali, et al. [31] 2020 Italy challenges in recycling
and complex and leads to an
processes of LIBs
uneconomically viable industrial-scale
application option.
3. There is a strong fragmentation of the
current recycling processes, which
should be integrated to overcome the
economic and environmental criticalities
for the high material yield in the
recycling process.
1. Cost of electricity is one of the
significant barriers to a low recycling
process. Places, where the price is
cheaper should be given priority to
Disposition alternatives of
Fujita, et al. [32] 2021 China establishing recycling plants.
spent LIBs in automotive
2. Reuse and recycling technologies must
address the cost and environmental
pollution with social systems and
regulations.
1. Governments, manufacturers,
recyclers, and end-users have a district
role in the battery value chain.
Sustainability of LIBs
Yang, et al. [33] 2021 China 2. Industries should pursue the CE
industry
approach and sustainability-inspired
technologies towards achieving
sustainability.
1. Regulatory support, economic
recovery methods, and spent battery
Recycling of lead-acid
Yanamandra, et al. [34] 2022 USA separation at source are the main success
batteries
factors for lead-acid battery recycling
systems in USA and Europe.
1. Reuse is the economic step before
End of life (EOL) vehicle recycling as it provides some time for
Kotak, et al. [35] 2021 Germany
batteries recycling companies to develop energy
and cost-efficiency methods.
1. Current commercial processes should
be altered for 100% recyclability of spent
LIBs.
physical processes for safe 2. Opportunities lie in the separation of
Sommerville, et al. [36] 2020 UK
spent LIBs recycling black mass post cell disassembly or
comminution, which tends to optimize
the process of short or direct loop
recycling.
Recycling 2022, 7, 33 6 of 40
Table 1. Cont.
Year of Country of
Reference Focus of the Study Major Findings
Publication Publication
1. Literature related to LiCoO2 cathodes
was widely discussed, while most of the
innovative recycling technologies using
spent automotive batteries were limited
Duarte Castro, et al. [37] 2022 Italy Spent LIBs valorization
to lab-based studies.
2. Economic aspects and environmental
impacts of the technologies require
further assessment.
1. Regulation, the economic advantage of
bulk shipping, and warehouse facilities
will be the critical components of the
spent LIBs ecosystem from the
EOL LIBs in perspective of safe battery transportation.
Slattery, et al. [38] 2021 USA
Transportation sector 2. Reverse supply chain mechanism and
responsible stakeholders involved in the
EOL LIB ecosystem should be identified
to develop the collection and recycling
system policy.
1. Further research is required on the
economics of EV recycling systems, the
role of power electronics, the
applicability of circular economy, and
D’Adamo and Rosa [39] 2019 Italy EOL EV management recycling activities around CE models.
2. Waste management and the renewable
energy sector can contribute to the
further development of the EOL EV
management sector.
1. Lack of socio-economic research is a
barrier to effective policy implementation
solar photovoltaic and
2. Systems modeling approach could be
Salim, et al. [40] 2019 Australia battery energy storage
an important research scheme to identify
systems
stakeholders and complex dynamics in
the battery energy storage value chain.
1. New analytical methods for battery
chemistries optimization should be
performed along with interdisciplinary
research.
2. Potential areas of investigation are
Grey and Tarascon [41] 2017 UK Battery monitoring system battery health record monitoring system,
use of optical fibers for monitoring and
assessment related readouts, and
integration of switch-on repair
mechanisms in the original battery
design.
1. There is scope for improvement in the
battery chemistries and cells.
Future perspectives of 2. Battery storage devices should be
Fichtner, et al. [42] 2022 Germany
Rechargeable Batteries made based on sustainable material and
more energy and performance, which
requires more R&D in the battery sector.
1. Bioelectrochemical systems have
remarkable potential for metal recovery
from LIBs.
2. The early stage is that metal recovery
Sethurajan and Gaydardzhiev Bioprocessing of spent from LIBs using a biotechnological
2021 Belgium
[43] LIBs for metal recovery process.
3. Bioleaching parameters should be
optimized, and pregnant leach solution
as part of the biological metal recovery
techniques should have further research.
Recycling 2022, 7, 33 7 of 40
Recycling 2022, 7, x FOR PEER REVIEW 4 of 39
Figure 2. General flow diagram of the recycling process of LIBs, compiled and redrawn from [17–
Figure 2. General flow diagram of the recycling process of LIBs, compiled and redrawn from [17–20].
20].
2018
2019
2020
2021
2022
Recycling 2022, 7, 33 8 of 40
Table 2. Number of publications by year and journal outlets (Data retrieved from Web of Science core
collection database from 2017–January 2022).
2017
2018
2019
2020
2021
2022
Journal Outlet Grand Total
ACS Sustainable Chemistry & Engineering 1 1 3 5
Advanced Sustainable Systems 1 1
Applied Sciences-Basel 1 1
Batteries-Basel 1 1 2
Chemical Engineering Journal 1 1
Chemie Ingenieur Technik 2 2
Chemsuschem 1 1 2
Energies 1 1 2
Energy 1 1
Energy Policy 1 1
Energy Storage Materials 1 1
Environmental Science & Technology 1 1 2
Frontiers In Energy Research 1 1
Frontiers In Materials 1 1
Hydrometallurgy 1 1
Journal Of Cleaner Production 1 1 2
Journal Of Energy Storage 2 1 3
Journal Of Environmental Chemical Engineering 1 1 2
Journal Of Environmental Management 1 1
Journal Of Industrial Ecology 1 1
Journal Of Physics-Materials 1 1
Journal Of Property Planning and Environmental Law 1 1
Journal of the Electrochemical Society 1 1
Materials 1 1
Metals 3 2 5
Minerals 1 1
Nature Sustainability 1 1
Proceedings of the Institution of Mechanical Engineers Part
1 1
I-Journal of Systems And Control Engineering
Resources Conservation and Recycling 1 10 11
Separation And Purification Technology 1 1
Surface Innovations 1 1 2
Sustainability 2 2
University Politehnica of Bucharest Scientific Bulletin Series
1 1
B-Chemistry and Materials Science
Waste Management 1 1 1 3
Waste Management & Research 1 1
Grand Total 1 3 9 14 36 3 66
Figure 4. Main subject areas of the reviewed articles (Years of analysis: 2017–January 2022).
Figure 4. Main subject areas of the reviewed articles (Years of analysis: 2017–January 2022).
Table 3. Distribution of papers based on the research fields in lithium-ion battery recycling.
Table 3. Distribution of papers based on the research
Major Subject/Research Field
fields in lithium-ion battery recycling.
References
Albertsen, Richter, Peck, Dalhammar and Plepys [14], Olsson, Fallahi, Schnurr, Diener and van Loon [15], Wralsen,
Business model
Major Subject/Research Field Prieto-Sandoval, Mejia-Villa, O’Born, Hellstrom and Faessler [7], Schulz-Monninghoff, et al. [44]
References
Disassembly Marshall, et al. [45], Gloser-Chahoud, et al. [46]
Policy and regulation Albertsen, Richter, Peck, Dalhammar andetPlepys
Giosue, al. [47] [14], Olsson, Fallahi, Schnurr, Diener and
Business model Kumar, et al. [48],
van Loon Baars,
[15], et al. [49], Chan,
Wralsen, et al. [50,51], Schwich,
Prieto-Sandoval, et al. [52,53], Diaz,
Mejia-Villa, et al. [54],
O’Born, Takahashi, and
Hellstrom et al. [55], Rey,
Faessler [7],
et al. [56], Peng, et al. [57], Cerrillo-Gonzalez, et al. [58], Ruismaki, et al. [59], Kaiser, et al. [60], Pavon, et al. [61,62], Peng,
Recovery only
Schulz-Monninghoff, et al. [44]
et al. [63], Liivand, et al. [64], Martinez, et al. [65], Bai, et al. [66], Liu, et al. [67], Karabelli, et al. [68], Chernyaev, et al. [69],
Grandjean, et al. [70], Rastegarpanah, et al. [71], Hou, et al. [72], Danczak, et al. [73], Grandjean, et al. [74], Torabian, Jafari
Disassembly Marshall, et al. [45], Gloser-Chahoud, et al. [46]
and Bazargan [9]
PolicyRecovery and recycling
and regulation Dunn,
Giosue, et al. et
[75]al. [47]
Paper focus—Anode material: Hou, et al. [76] (Expired-oxytetracycline), Dai, et al. [77] (expired aminophylline),
Kumar, et
Paper focus—Cathode al. [48],
material: Baars,et et
dos Santos, al. (Co,
al. [78] [49], Ni,Chan,
Mn, Li), et al. [50,51],
Roldan-Ruiz, et al.Schwich, et al.
[79] (Li and Co), [52,53],
Vieceli, et al.
[80] (Li, Mn, Ni and Co), Rambau, et al. [81] (Mn), Tan, Wang, Chen, Li, Sun, Liu, Yang, Xiang, Sun and Duan [82] (Ni,
Diaz, et al. [54], Takahashi, et al. [55],
Co, Mn), Charles, et al. [83] (Co, Li and graphite), Piatek, et al. [84] (Co, Ni),
Rey, et al. [56], Peng, et al. [57],
Recycling only BothCerrillo-Gonzalez,
cathode and anode material: et al. [58], Ruismaki,
Sommerfeld, et al.and
et al. [85] (lithium [59],
mixedKaiser, et al.and
cobalt, nickel, [60], Pavon,
copper alloy), et al. [61,62],
Recovery only Sommerville,
Peng, et et al.
al.[86][63],
(commercial
Liivand, recycling technologies
et al. in general),et
[64], Martinez, Sadhukhan
al. [65],and Christensen
Bai, [87] (LCA
et al. [66], Liu,including
et al. [67],
recycling process of battery energy storage system), Velazquez-Martinez, et al. [88] (Al, Cu, Li, Ni), Rinne, et al. [89] (Cu,
Karabelli, et al. [68], Chernyaev, et al. [69], Grandjean, et al. [70], Rastegarpanah,
Al, Ni, Co, Li, Mn), Pavon, et al. [90] (Co, Cu, FE, Ni and Mn), Thompson, et al. [91] (Co, Mn, Fe, Li, Al, Ni), Hsieh, et al.
et al.
[92] (Co,[71], Hou,
Ni, Li), et al. [72],
Chabhadiya, Danczak,
et al. [93] (Cu, Li, Ni,etMn,al.Li)[73], Grandjean, et al. [74], Torabian, Jafari and
Recycling and reuse Bazargan
Natarajan, et al. [94][9]
Reuse only Wewer, et al. [95], Richa, et al. [96], Ciobotaru, et al. [97], Gucciardi, et al. [98]
Recovery andmanagement
Waste recycling Dunn,etetal.al.
Ahuja, et al. [99], Lagae-Capelle, [75]
[100], Castro, et al. [101]
Paper focus—Anode material: Hou, et al. [76] (Expired-oxytetracycline), Dai, et al. [77]
When the main research focus is considered, experimental studies are the most dom-
(expired aminophylline),
inant category Paper
among others, followed by evaluation-,
focus—Cathode material: dos Santos, planning-,
et al. [78]and(Co,simulation-type
Ni, Mn, Li),
studies (Figure 5). In Table 1, it is found that less attention was given
Roldan-Ruiz, et al. [79] (Li and Co), Vieceli, et al. [80] (Li, Mn, to socio-economic
Ni and Co),
and techno-economic
Rambau, et al. [81]research
(Mn), topics.
Tan, Wang,A similar
Chen,trend has Liu,
Li, Sun, beenYang,
identified
Xiang,inSun
thisand
article
Duanas [82]
well (i.e., decision-making and planning-related
(Ni, Co, Mn), Charles, et al. [83] (Co, Liissues were highlighted
and graphite), Piatek, etless). Therefore,
al. [84] (Co, Ni),
Recycling only it shouldBoth
be considered
cathode andananode
emerging research
material: opportunity
Sommerfeld, et al.in[85]
the(lithium
future. and
In this review,
mixed cobalt,
articlesnickel,
were reviewed
and copper according to the categorization
alloy), Sommerville, made
et al. [86] under therecycling
(commercial researchtechnologies
focus. The in
analysisgeneral),
of the articles is presented
Sadhukhan in the following
and Christensen sections.
[87] (LCA including recycling process of battery
energy storage system), Velazquez-Martinez, et al. [88] (Al, Cu, Li, Ni), Rinne, et al. [89]
(Cu, Al, Ni, Co, Li, Mn), Pavon, et al. [90] (Co, Cu, FE, Ni and Mn), Thompson, et al. [91]
(Co, Mn, Fe, Li, Al, Ni), Hsieh, et al. [92] (Co, Ni, Li), Chabhadiya, et al. [93] (Cu, Li, Ni,
Mn, Li)
Recycling 2022, 7, 33 10 of 40
Table 3. Cont.
When the main research focus is considered, experimental studies are the most dom-
inant category among others, followed by evaluation-, planning-, and simulation-type
studies (Figure 5). In Table 1, it is found that less attention was given to socio-economic
and techno-economic research topics. A similar trend has been identified in this article as
well (i.e., decision-making and planning-related issues were highlighted less). Therefore,
it should be considered an emerging research opportunity in the future. In this review,
Recycling 2022, 7, x FOR PEER REVIEW 9 of 39
articles were reviewed according to the categorization made under the research focus. The
analysis of the articles is presented in the following sections.
Figure 5. Main research focus of the articles (Years of analysis: 2017–January 2022).
Figure 5. Main research focus of the articles (Years of analysis: 2017–January 2022).
3.1.Analyzing
3.1. AnalyzingEvaluation
Evaluation Study
Study
Toestablish
To establish aa sustainable
sustainableLIB circular
LIB economy
circular economy andand
based on theon
based existing knowledge
the existing knowl-
of lead-acid battery recycling, Sommerville, Zhu, Rajaeifar, Heidrich,
edge of lead-acid battery recycling, Sommerville, Zhu, Rajaeifar, Heidrich, GoodshipGoodship andand
Kendrick [86] thoroughly assessed the automobile battery recycling process.
Kendrick [86] thoroughly assessed the automobile battery recycling process. According According to to
the authors, there are numerous improvement opportunities currently available
the authors, there are numerous improvement opportunities currently available for LIBS for LIBS
recycling procedures and better chances for the reuse and recycling of valuable materials.
recycling procedures and better chances for the reuse and recycling of valuable materi-
They found that most recycling operations are designed to recover rich metals and occa-
als. They found that most recycling operations are designed to recover rich metals and
sionally graphite, with less attention paid to other materials such as solvents, plastics, lith-
occasionally graphite, with less attention paid to other materials such as solvents, plastics,
ium salts, and phosphorus. Current and future economic analyses of these recycled mate-
lithium salts, and phosphorus. Current and future economic analyses of these recycled
rials from evolving methods are required. The authors anticipated that incentives to create
materials from evolving methods are required. The authors anticipated that incentives
new markets that can use the recovered elements would be necessary for some circum-
to create new markets that can use the recovered elements would be necessary for some
stances. This will be aided by more research into the lifetime trade-offs of produced emis-
circumstances. This will be aided by more research into the lifetime trade-offs of produced
sions when using the current systems’ defined processes.
emissions when using the current systems’ defined processes.
Sadhukhan and Christensen [87] studied a thorough life cycle assessment (LCA) of
Sadhukhan and Christensen
battery energy storage [87] studied
systems (BESS) a thorough
using LIBs followinglife cycle assessment
ISO14040-44. (LCA) of
The research
battery
goal wasenergy storageBESS’s
to compare systems (BESS)
global using LIBs
warming following
potential ISO14040-44.
to a globally The research
harmonized goal
life cycle
was to compare BESS’s global warming potential to a globally harmonized
inventory database for LIBs with a lithium manganese oxide cathode. The authors con-life cycle inven-
cluded that BESS could be optimized for its multifaceted integrated contributions to max-
imize carbon footprint reductions in the power industry.
Rey, Vallejo, Santiago, Iturrondobeitia and Lizundia [56] conducted a LCA on graph-
ite recycling from Spent LIBs. They compiled ReCiPe 2016 midpoint impact categories
Recycling 2022, 7, 33 11 of 40
tory database for LIBs with a lithium manganese oxide cathode. The authors concluded
that BESS could be optimized for its multifaceted integrated contributions to maximize
carbon footprint reductions in the power industry.
Rey, Vallejo, Santiago, Iturrondobeitia and Lizundia [56] conducted a LCA on graphite
recycling from Spent LIBs. They compiled ReCiPe 2016 midpoint impact categories (with
18 standardized items), assessing the environmental impacts of the recycling processes
and upcycling of graphite. For example, decreasing the number of acids used can lessen
particular consequences by 73%.
Bobba, et al. [102] discussed the significance of recycling in reducing the supply risk
of Li and Ni, which are both used in LIBs, by employing a material flow analysis and LCA
as core methods. Overall, it is proposed that critical features of a priority sector for the EU,
such as mobility, be identified using a combination of the information offered by different
tools and specialists in diverse industries and by assessing possible scenarios. Furthermore,
according to various criticality assessments conducted internationally, the supply risk for
Ni is substantially lower than that for Li; therefore, recycling as a risk mitigation component
looks to be even more relevant for Li than for Ni.
Ciobotaru, Benga and Valreanu [97] presented a calculus for the energy consumption
of the reconditioning process of Lion batteries. The authors found that recycling valuable
components, primarily metals such as copper, nickel, cobalt, and lithium, and their reuse
in diverse applications is a contemporary practice when dealing with wasted lithium-ion
batteries. Furthermore, the representation of the reconditioning degree in three out of every
twenty lithium-ion batteries has a reconditioning degree of less than 60%, indicating that
these samples are likely to be recycled.
The waste management hierarchy is a conceptual framework postulated from a life-
cycle thinking approach to guide and rank waste management decisions based on the
priorities (e.g., waste prevention, reuse, recycling, (energy) recovery, and final disposal)
that are needed for environmental benefits. Ali, Khan and Pecht [13] summarized LIBs’
waste management hierarchy, arguing that reuse is preferable to recycling in terms of
financial gain and environmental impact. They also mentioned that the direct recycling
process involves the extraction of anode and cathode material from LIBs for remanufac-
turing and reuse. They concluded that further process innovation is needed to improve
the financial and environmental feasibility of recycling LIBs. In addition to the traditional
waste management hierarchy scheme, circular thinking (i.e., the three principles of circu-
lar economy: (1) eliminate waste and pollution, (2) use the products and materials for a
longer duration of time, and (3) regenerate natural ecosystems) has been integrated into
the framework to delay or avoid disposal-related flows, especially for EoL EV batteries,
for the realization of the economic benefits of reuse and recycling. Richa, Babbitt and
Gaustad [96] developed a conceptual framework (shown in Figure 6) in this regard and
described it as a CE-centric waste management hierarchy. The authors found that a circular
waste management hierarchy could recover around 77% of the cumulative energy demand
(CED) and 30% of the eco-toxicity effect associated with the battery’s initial manufacture.
A CE-centric waste management hierarchy may be helpful in the future for managing the
EV LIB waste stream. Still, the eco-efficiency of the many EOL pathways that make up the
system is uncertain. To realize the anticipated benefits of EV LIB, cascaded use, regulations,
and economic incentives must be in place before recycling.
According to Dunn, Slattery, Kendall, Ambrose and Shen [75], LIB cathode material
recovery and recycling could meet a significant portion of future material demand, thereby
reducing the demand for virgin material, reducing battery waste, and potentially lowering
the environmental impact of new batteries if recycling is less environmentally intensive
than primary production. The authors also suggested that policy involvement is necessary
because future EV LIBs will likely contain lower-value components. The need for policy
involvement is heightened by the potential for lower-value materials in future EV LIBs.
LIB recycling is a new business, and policymakers have the chance to ensure a material
supply by encouraging domestic recycling.
Recycling 2022, 7, 33 12 of 40
authors, in the progressive scenario, where NMC cathode demand is solely met by NMC
811 chemistry, nickel demand in 2030 would reach 34% of the current mining output.
Currently, EoL battery treatment involves physical disassembly followed by essential
recycling of critical cathode elements. Gloser-Chahoud, Huster, Rosenberg, Baazouzi,
Kiemel, Singh, Schneider, Weeber, Miehe and Schultmann [46] emphasized the industrial
disassembly of electric vehicle battery systems for enhanced levels of material circularity for
the waste stream. According to the authors, the traction battery is the electric vehicle’s most
resource- and energy-intensive component. The theoretical industrial disassembling system
detailed in the study will necessitate changes to the battery and12 vehicle
Recycling 2022, 7, x FOR PEER REVIEW of 39 design to simplify
the disassembly and additional technical advancements in constructing robot-assisted,
highly automated EVB disassembly lines. The authors also mentioned that second-life
most resource-
concepts doand
notenergy-intensive
directly competecomponent.
withThe theoretical industrial
recycling in termsdisassembling
of EoL treatment; instead, they
system detailed in the study will necessitate changes to the battery and vehicle design to
merely extend the valuable lifetime of battery systems, modules,
simplify the disassembly and additional technical advancements in constructing robot- or cells.
assisted, highly automated EVB disassembly lines. The authors also mentioned that sec-
ond-life
3.2. concepts do
Analyzing not directly compete
Experimental Studieswith recycling in terms of EoL treatment; in-
stead, they merely extend the valuable lifetime of battery systems, modules, or cells.
This section of the review considered pre-treatment processes such as discharge,
dissolution, and separation-related
3.2. Analyzing Experimental Studies articles. On the other hand, acid leaching and water
leaching processes
This section under
of the review hydrometallurgy
considered and slag
pre-treatment processes suchcleaning-related
as discharge, dis- articles under the
solution, and separation-related
pyrometallurgical processarticles. On the otherThe
are reviewed. hand,co-recycling
acid leaching and of water
spent LIBs with different
leaching processes under hydrometallurgy and slag cleaning-related articles under the
types of waste process
pyrometallurgical has received considerable
are reviewed. attention,
The co-recycling of spentalong withdifferent
LIBs with the potential opportunities
around material
types of waste reuseconsiderable
has received and remanufacturing. Therefore,
attention, along with the potentialtheopportunities
articles retrieved from the data
around material
collection reuseare
stages andonly
remanufacturing.
reviewedTherefore, the articles
in this section retrieved
under thefrom the
experimental studies. The
data collection stages are only reviewed in this section under the experimental studies.
pre-treatment process and other recycling processes of LIBs can
The pre-treatment process and other recycling processes of LIBs can be shown in Figure
be shown in Figure 7. The
experimental
7. The experimentalstudies
studies are summarized
are summarized in Table
in Table 4. 4.
Comminution
Dismantling/ Classification
Discharge (mechanical Separation
disassembly (sieving)
treatment)
Thermal Pretreatment
Dissolution
treatment stages
Direct
Hydrometallurgy Pyrometallurgy
recycling
process process
process
Acid leaching/
Pre-heating Spent cells
reductive Supercritical
(<300°C) after
leaching CO2
dismentling
Residue
Pyrolysis
Seperation (>700°C) Low-
Physical
temperature/
seperation
pressure
Smelting
Metal-ion reduction
solution
Electrolyte Spent cathode
Slag
Product Sintering
Further
hydrometallurgical
process
Cathodes
Li2CO 3
Figure 7. Pre-treatment and various recycling processes of waste LIBs (partially adopted from
Kim, et al. [104] and Zhou, et al. [105]).
Recycling 2022, 7, 33 14 of 40
Table 4. Summary of the experimental studies on lithium-ion battery recovery and recycling.
Experimental
Country of Recoverable Yield of Other Further Comment
Reference Name of the Process
Publication Lithium Yield from Metals on the Process
the Process
Sommerfeld, Pyrometallurgical
Higher quartz
Vonderstein, approach—Smelting In the metal alloy,
addition increased
Dertmann, Klimko, operation using Cobalt—81.6%
Germany 82.4% the lithium yield but
Orac, Miskufova, suitable slag design Nickel—93.3%
deceased lithium
Havlik and Friedrich in laboratory electric Copper—90.7%
content in the slag
[85] arc furnace
Removal rates from
the waste carbon
The WCR
residue (WCR),
purification process
Cobalt—99.59%
Zhu, Xiao, Mao, low-temperature is economically cost
Nickel—99.54%
Zhang, You, Tang China fluorination roasting 99.23% effective around
Manganese—99.82%
and Zhong [106] and water leaching $3.654/kg. Recycled
Aluminum—96.38%
ammonium fluoride
silicon—98.41%
is like virgin material.
Iron—97.28%
Sulfur—98.61%
Inexpensive reagent
Hydrometallurgy-
use, low
dos Santos, Garde, based
environmental
Ronchini, Cardozo, technology—The lithium nickel
98% as lithium cobalt impact, low
de Souza, Abbade, Brazil RecycLib technology, manganese cobalt
oxide LiCoO2 (LCO) operating cost, high
Regone, Jegatheesan considered as oxide (NMC)—85%
work safety with
and de Oliveira [78] upstream recycling
potential for
technology
industrial scalability
This process is
considered as
high-recovery
Hydrometallurgical
recycling process
process—Closed- ∼100% (lithium is
Chan, Anawati, Cobalt, Nickel, and which will be
Canada Loop Recycling, precipitated as
Malik and Azimi [50] Manganese ~100% applicable to
recycled cathode lithium carbonate)
fast-growing LIB
material
industry. There is a
scope for integrating
the processing steps.
MIL-53 the output
2.5 g of Al MOF at 70 material has similar
Formation of and 90 ◦ C from 5 g of properties of pure
Lagae-Capelle, high-quality crushed batteries chemical compounds.
Cognet, Madhavi, Al-MOF-type porous (containing 240 mg of Use of greener
France -
Carboni and Meyer material from PET Al) and 3 g of plastic solvent (instead of
[100] plastics and Li-ion bottles (containing Dimethylformamide)
battery waste 1.8 g of the organic and energy use
ligand) would optimize the
process.
The process can
prevent
solvent extraction contamination of
Lu, Stevens and technology using different solvent.
Australia - -
Mumford [51] organo-phosphinic With the process,
acid lithium can be
extracted at high pH
range (5.5–8.0).
Low recycling cost
and high recovery
Two-step
rate was achieved in
Hou, Dai, Liu, Yaol, carbonization process
China - - direct process, while
Yu and Li [76] for anode material
indirect process route
production of LIBs
has broader
application scope.
Recycling 2022, 7, 33 15 of 40
Table 4. Cont.
Experimental
Country of Recoverable Yield of Other Further Comment
Reference Name of the Process
Publication Lithium Yield from Metals on the Process
the Process
Electrochemical
Ultrasonication had
discharge using salt
Torabian, Jafari and an impact of
Iran solutions for - -
Bazargan [9] discharge
avoidance of
performance.
handling hazards
“ESLR” method has
advantages over
Early-stage lithium ordinary
Schwich, Schubert recovery (“ESLR”) H2 O-leaching and
Germany 79% -
and Friedrich [52] using Supercritical that the indirect
CO2-Carbonation carbonation
mechanism is
favourable.
electrowon Cu and
Diaz, Strauss,
Co, Ni, and graphitic carbon can
Adhikari, Klaehn, Electrochemical
USA >96% Mn—>96% (leaching be obtained as by
McNally and Lister leaching
efficiencies) product in the metal
[54]
leaching process
The knife mill was
Takahashi, Botelho, Solvent extraction Co—91%
the only one who
Espinosa and Tenorio Brazil and leaching-based - (leaching—solvent
was able to ground
[55] Co extraction Extraction)
the batteries.
In any event, it
demonstrates that
several of the
examined techniques
are environmentally
competitive with raw
graphite while also
avoiding waste
Rey, Vallejo, Santiago, management
LCA of Graphite
Iturrondobeitia and Spain - - difficulties associated
Recycling
Lizundia [56] with uncontrolled
battery disposal.
These findings
highlight the value of
recycling and
upcycling as methods
for obtaining
materials with lesser
environmental effect.
This unique
technique not only
improves LIBs waste
leaching efficiency,
but it also improves
Hydrometallurgy—
Peng, Liu, Aji, Wilson extraction total Co and Li
Finland acid Co—99%
and Lundstrom [57] efficiencies—99% recovery from LIBs
Dissolution
waste, even from the
bigger particle size
fractions that are
generally lost in
circulation.
Recycling 2022, 7, 33 16 of 40
Table 4. Cont.
Experimental
Country of Recoverable Yield of Other Further Comment
Reference Name of the Process
Publication Lithium Yield from Metals on the Process
the Process
Without the reducing
agent, p-toluene
sulfonic acid
monohydrate (PTSA)
and choline
chloride (ChCl)
Roldan-Ruiz, Ferrer, p-Toluenesulfonic (PTSAChCl)-based
Gutierrez and del Spain Acid-Based Cathode - Co—94% deep eutectic
Monte [79] Recycling Solvents (DESs)
showed excellent Li
and Co solvent
capabilities at low
temperatures, short
times, and low
amounts of solvent
The proposed model
can be extended to
other cathodes’
Cerrillo-Gonzalez, chemistry and
Villen-Guzman, extracting agents
Hydrometallurgical 65–70% (extraction
Acedo-Bueno, Spain - along with the
Extraction efficiency)
Rodriguez-Maroto experimental
and Paz-Garcia [58] observation of using
a reducing agent and
temperature during
the leaching process
lower temperatures
of incineration
(400–500 ◦ C) and at
Vieceli, Casasola, Hydrometallurgical
70% (leaching Mn, Ni and Co—70% higher leaching times
Lombardo, Ebin and Sweden recycling using
efficiency) (leaching efficiency) are associated to
Petranikova [80] sulfuric acid
partial carbothermic
reduction of
the metals.
Further refinement
by pyrometallurgical
Ruismaki, Rinne, Flotation and or
Danczak, Taskinen, Pyrometallurgy- hydrometallurgical
Finland - Co—81.3%
Serna-Guerrero and based graphite procedures is
Jokilaakso [59] recovery required to isolate the
precious metals, such
as Co, Ni, and Cu.
The developed LIBs
recycling strategy has
the potential to
Rambau, Musyoka, Manganese-Based 99% coulombic
complement existing
Palaniyandy and South Africa Metal Organic - efficiency (discharge
LIBs recycling
Manyala [81] Framework specific capacity)
techniques while also
contributing to the
circular economy.
85% of the batch of
batteries were prone
Ciobotaru, Benga and
Bucharest Reconditioning - - to undergo
Valreanu [97]
reconditioning
process.
Recycling 2022, 7, 33 17 of 40
Table 4. Cont.
Experimental
Country of Recoverable Yield of Other Further Comment
Reference Name of the Process
Publication Lithium Yield from Metals on the Process
the Process
Al (1.2 ± 0.02 mg
L−1 ;
99.7 ± 1.07%),
Co (3.7 ± 0.12 mg
L−1 ; 99.8 ± 0.78%),
This is a holistic
Cu
recycling process for
(3.1 ± 0.48 mg L−1 ;
COOL-process LIB that can recover
Pavon, Kaiser and Li-free black 97.8 ± 1.46%),
Germany (counter-current housing material,
Bertau [61] mass Fe (0.8 ± 0.21 mg
solvent extraction) lithium
L−1 ;
and the
98.5 ± 0.65%),
accompanying metals
Mn (38.3 ± 0.91 mg
L−1 ; 99.9 ± 1.11%),
and
Ni (14.4 ± 2.1 mg
L−1 ; 98.6 ± 1.32%)
Leaching efficiency Elevating
using 2N H2 SO4 and reaction temperature
4N HCl acid, as well as extending
Kaiser, Pavon and
Germany COOL process - Co—63.2–63.8%, reaction
Bertau [60]
Cu—63.8–80.1% time would enhance
Mn—66.4–79.9% the leaching
Ni—50.4–63.3% efficiency
The utilization of
fruit peel trash to
recover valuable
CO—>73% (recovery metals from wasted
around 90%
Hydrometallurgical efficiency) LIBs is a
Wu, Soh, Chan, (recovery efficacy in
Processes—Leaching Mn and Ni- around cost-effective,
Meng, Meyer, LIB
Singapore with green Reductant 90% (recovery environmentally
Srinivasan and Tay black
(orange peel powder efficacy in LIB black benign, and
[62] mass-containing
(OP) mass-containing long-term method for
leaching liquor)
leaching liquor) reducing both waste
kinds’ of
environmental
impact.
Selective leaching of
Co and Li vs. Cu was
proposed and
achieved in a sulfuric
Peng, Hamuyuni, Reductive leaching of
Co—93.8%, acid system at 80 ◦ C
Wilson and Finland cobalt and lithium in 95.7%
Cu—0.7%, with a leaching time
Lundstrom [63] sulfuric acid system
of 90 min with
C6 H8 O6 introduced
at the start of the
leaching process.
In comparison to
commercial
Graphite recovery nitrogen-doped
Liivand, Kazemi,
(for valuable catalyst graphene, NG-Bat
Walke, Mikli, Uibu,
Estonia material for - - made from SLIB
Macdonald and
Electrochemical demonstrated
Kruusenberg [64]
Oxygen Reduction) improved physical
and electrochemical
properties.
Recycling 2022, 7, 33 18 of 40
Table 4. Cont.
Experimental
Country of Recoverable Yield of Other Further Comment
Reference Name of the Process
Publication Lithium Yield from Metals on the Process
the Process
This cost-effective
and ecologically
beneficial separation
Ethylene
Bai, Muralidharan, Li, technique not only
glycol-based solvent
Essehli and - - delivers a closed-loop
recovery system for
Belharouak [66] recycling solution,
direct recycling
but also propels
battery recycling into
a new paradigm.
Cost of LFP recycling
Recovering of used
will be low with the
FePO4 electrodes
proposed material
Gucciardi, Galceran, from calendar aged
alternative while also
Bustinza, Bekaert and Spain Lithium-ion (Li-ion) - -
lowering
Casas-Cabanas [98] batteries and use it in
environmental effect
Sodium-ion (Na-ion)
and encouraging
cells
sustainability.
In this method no
simultaneous
oxidant or reductant
Liu, Peng, Porvali, recycling of LIBs and
Co—98% additions required,
Wang, Wilson and China nickel−metal >93%
Ni—98% and it is environment-
Lundstrom [67] hydride batteries
friendly and
(NiMHs)
economic
This is a zero
Co, Cu, Fe, Ni, and waste-approach for
Pavon, Kaiser, Mende
Germany COOL-Process 99.05 ± 0.64 wt.% Mn—(97.7 wt.%) in recovering Li from
and Bertau [90]
solid residue primary and
secondary sources
According to the
authors, 11 g of
Leaching of copper (0.75 Cu/Co,
Chernyaev, Partinen, pre-treated mol/mol), 4.8 g of
Klemettinen, Wilson, LiCoO2 -rich battery Co leaching—47% aluminum (0.7
Finland -
Jokilaakso and waste (use of Cu and Cu (66%) Al/Co, mol/mol) or
Lundstrom [69] Al current collector a combination of both
as reductants) were the optimum
required recipe for
full cobalt extraction.
With the experiment,
the potential reuse
and remanufacture of
individual LIB cells
from a complete
damaged pack is
Grandjean, Flash cryogenic made easier,
Groenewald and UK freezing for battery - - extending the useful
Marco [70] reverse logistics life, lowering raw
material
consumption, and
boosting the
environmental
sustainability of EV
adoption.
Piatek, Budnyak, By substituting some
Green
Monti, Barcaro, of the coordinated
Metal−Organic
Gueret, Grape, water molecules in
Sweden Framework for - 30% of Ni2+ recovery
Jaworski, Inge, the MOF tubes, the
CO-Ni selective
Rodrigues and Ni2+ ions were more
seperation
Slabon [84] likely to enter.
Recycling 2022, 7, 33 19 of 40
Table 4. Cont.
Experimental
Country of Recoverable Yield of Other Further Comment
Reference Name of the Process
Publication Lithium Yield from Metals on the Process
the Process
Biodegradable
H2 C2 O4 and low
emission H2 SO4 are
Two-step leaching
not only suitable for
Chabhadiya, process
≥99% (in selective Cu—≥ 99% (in environment-
Srivastava and India (LiNixCoyMnzO2
dissolution) selective dissolution) friendly valorization
Pathak [93] type exhausted
of waste but also
cathode material)
cost-effective for
downstream
processing
High specific surface
area (492 m2 /g) and
Waste bio-based structural defects
Hou, Yu, Liu, Yao, material use in anode induced by
China - -
Liao, Dai and Li [72] for LIBs using carbonization process
carbonization process enhanced the
electrochemical
performance
Danczak, Ruismaki,
Integrated froth Industrial-scale
Rinne, Klemettinen,
flotation and process of the
O’Brien, Taskinen, Finland - -
nickel-slag cleaning method should be
Jokilaakso and
process performed
Serna-Guerrero [73]
Discharging Process
Torabian, Jafari and Bazargan [9] proposed a detailed and optimized scheme for the
discharge process of waste LIBs (electrochemical discharge using salt solutions), in which
sediments and the corrosion of the electrodes were entirely avoided with no anode and
cathode short-circuiting risk (fire hazard). The authors demonstrated this process with six
Apple iPhone batteries (3.82 V each) with NaCl, Na2 S, and MgSO4 solutions. Grandjean,
Groenewald, McGordon and Marco [74] considered the waste battery transportation and
reverse logistics and performed a lifecycle analysis of LIBs after flash cryogenic freezing.
Cell impedance and capacity were monitored at regular intervals during cycling to quantify
any impacts of flash freezing on cell aging and performance degradation. No statistical
difference in cell function was identified between the flash-frozen and control groups at a
95-percent confidence level on two cell chemistries and form parameters. Therefore, flash
cryogenic freezing won’t shorten the life of batteries or cause them to age prematurely.
Recycling 2022, 7, 33 20 of 40
Separation
The LIB recycling techniques all have one thing in common: lithium can only be
separated at the end of the chain. High losses, as well as contaminants in lithium carbonate,
are linked to this. Pavon, Kaiser and Bertau [61] demonstrated a four-stage counter-current
extraction process that separated Li from a mixture (Co, Li) from spent LIBs. The authors
proved that from LIB black mass derived from spent LIBs with high discriminatory power,
not only Li as Li2 CO, but also Al, Mn, and Ni, can be recovered, thereby significantly
contributing to the circular economy goals. However, the complete recycling process of LIBs
needs to be evaluated further from economic, technical, and environmental standpoints.
Despite numerous studies on Co recovery in spent LIBs recycling, processes related to
grinding had not been thoroughly investigated. Starting from grinding through selective
separation, Takahashi, Botelho, Espinosa and Tenorio [55] studied the entire cobalt recovery
process. The authors investigated the use of various grinding equipment and leaching
agents for recovery. The most efficient cobalt leaching method occurred when a temperature
of 50 ◦ C and pH at 3.0 for H2 SO4 + H2 O2 solutions were utilized. With this process, 91% of
Co was recovered after whole hydrometallurgical procedures, including leaching solvent
extraction.
Under mild conditions, Piatek, Budnyak, Monti, Barcaro, Gueret, Grape, Jaworski,
Inge, Rodrigues and Slabon [84] established a simple and green process for separating
Co and Ni from cobalt-nickel aqueous solutions. At pH 5–7, the ion-based microporous
metal–organic framework (MOF), SU-101, was suitable for Ni2+ ion absorption but not
for Co2+ ion absorption. The study’s findings revealed a green approach to recycling and
separating valuable metals from cobalt-containing LIBs and a circular economy waste
valorization path.
A polyvinylidene difluoride binder is widely used in LIB manufacturing; this is due to
its strong adhesion bonding capability and high chemical stability (i.e., separating cathode
materials and Al foil). However, this is a significant challenge for direct recycling and hy-
drometallurgical processes. Therefore, this pre-treatment is critical for increasing recycling
efficiency and lowering energy consumption related to later separation procedures. Bai,
Muralidharan, Li, Essehli and Belharouak [66] demonstrated an Ethylene glycol (EG)-based
solvent separation procedure to delaminate electrode components, including a cathode and
anode, from their current collectors in discharged Li-ion batteries efficiently and quickly.
The solvent was directly recycled and utilized for continuous delamination, which closed
the recycling loop without producing additional waste.
Dissolution
Using UV-vis spectroscopy, Roldan-Ruiz, Ferrer, Gutierrez and del Monte [79] studied
PTSAChCl-based DESs for Co and Li dissolution. Considering the entire process, the
adoption of PTSAChCl-based DESs resulted in a 94-percent overall recovery. The authors
mentioned that using high solid-to-liquid ratios (Rm/V) were particularly intriguing. This
considerable reduction in the solvent required for Co dissolution was both economically
and environmentally beneficial.
Peng, Liu, Aji, Wilson and Lundstrom [57] studied the effect of metallic elements on the
Li and Co acid dissolution process of waste LIBs generated from an industrial process. The
authors found that with varying percentages of metallic components, increased amounts of Cu
enhanced the leaching effectiveness of Li and Co while using industrial battery waste fractions.
They also found that the presence of Fe in solution is critical in acid leaching experiments with
pure metallic compounds, as it has a catalytic influence on the reductive behavior of both Al
and Cu, thereby resulting in leaching efficiencies of Co and Li of up to 100%.
Chabhadiya, Srivastava and Pathak [93] used a design of experiment for a two-step
leaching method for second-generation cathode material (LNCM) employing organic acid
and their process resulted in oxalic acid leaching of copper and lithium from the cathode
material. The authors discovered that cathode metal dissolution was due to the independently
Recycling 2022, 7, 33 21 of 40
controlled diffusion of the lixiviant media. They also highlighted that organic and mineral
acids have advantages such as selective leaching and high metal efficiency.
Cellulose
Conversion
Reducing sugars
(glucose, xylose,
Hemicellulose Precipitation and Regeneration
galactose Extraction reconstruction
mannose, etc.)
Li+
Orange peel
Co 2+
Blass mass LiCoO 2 LCO battery
Ni2+
Mn2+
Flavonoids Anioxidants
Phenolic acids
Figure 8. Mechanism and process summary of recycling of spent LIBs using orange peel (), redrawn
Figure 8. Mechanism and process summary of recycling of spent LIBs using orange peel (), redrawn
from Wu, Soh, Chan, Meng, Meyer, Srinivasan and Tay [62].
from Wu, Soh, Chan, Meng, Meyer, Srinivasan and Tay [62].
Liu,
Liu,Peng,
Peng,Porvali,
Porvali, Wang, Wilson and
Wang, Wilson andLundstrom
Lundstrom[67] [67]proposed
proposed a battery
a battery leaching
leaching
process
processwith
withsulfuric
sulfuric acid
acid (H₂SO₄)
(H2 SO4 ) that uses the
that uses theintrinsic
intrinsicfeatures
featuresofofLIBs
LIBs and
and nickel-metal
nickel-metal
hydride
hydride(NiMH
(NiMH battery) wasteas
battery) waste asreduction
reduction and
and oxidation
oxidation reagents
reagents thatthat
alsoalso reduce
reduce exter-
external
nal reagent
reagent use.use.
ThisThis
methodmethod does
does not not require
require any additional
any additional high-costhigh-cost
reagents inreagents in the
the leaching
leaching stage. Furthermore,
stage. Furthermore, because because the associated
the associated process wastewaters
process wastewaters were recircu-
were recirculated for
lated for rare-earth elements (REEs) recovery and ended up in the final residue, the Na+
rare-earth elements (REEs) recovery and ended up in the final residue, the Na+ and SO 2
that entered the process did not add any load on the environment. At the
and SO2 that entered the process did not add any load on the environment. At the same same time, the
residual
time, Li in the effluent
the residual Li in thewas returned
effluent wastoreturned
the process. Figure
to the 9 shows
process. the process.
Figure 9 shows the pro-
Cerrillo-Gonzalez, Villen-Guzman, Acedo-Bueno, Rodriguez-Maroto and Paz-Garcia [58]
cess.
presented a model for the extraction of lithium and cobalt from LiCoO2 particles, which
considers the switch in regulating mechanisms from chemical kinetics to mass transfer. The
model for lithium and cobalt extraction from LiCoO2 particles satisfactorily reproduces the
experimental results in various situations, thereby comparing the experimental observations
and simulations. Furthermore, the model can also estimate the non-equimolar fraction of Li+
and Co2+ extracted and the maximum extraction limitation caused by the creation of a Co3 O4
crust surrounding the particle’s core.
Using organic solvent Cyanex 272 (containing tributyl phosphate and kerosene), Lu,
Stevens and Mumford [51] showed the application of a solvent extraction technology from
synthetic leach solutions for lithium-ion recovery. The experimental process found that
pH, extractant concentration, and multivalent metal concentration had the highest impact.
On the other hand, temperature, ionic strength, monovalent metals (Na(I)), and modifier
concentration had a low impact on the process performance. Furthermore, the authors
showed that with the one-step process illustrated, other cathodic materials (e.g., Co, Ni)
could be recovered with the same solvent. Chernyaev, Partinen, Klemettinen, Wilson,
Jokilaakso and Lundstrom [69] utilized response surface modeling by considering the
acid consumption rate, Co extraction, and final acid concentration to generate a regression
equation that would allow the Cu extraction process to be optimized. The authors identified
Recycling 2022, 7, 33 23 of 40
Synergistic
leaching
Residue NaREEE(SO4)
(carbon) 2
Extraction of
REEs by
double sulfate
precipitation
Na2SO4
Recovery of
MnO 2
Mn, Co and Ni
CoSO4
Preparation of
Li3PO4
Na3PO4
NiSO4
Li3PO4
Figure9.
Figure 9. Recovery
Recovery of
of REEEs,
REEEs, Li,
Li, Ni
Ni and
and Co
Co using
using H
H₂SO₄ leaching process, redrawn from Liu, Peng,
2 SO4 leaching process, redrawn from Liu, Peng,
Porvali, Wang, Wilson and Lundstrom
Porvali, Wang, Wilson and Lundstrom [67].[67].
Cerrillo-Gonzalez,
Besides the acid leaching Villen-Guzman,
process, newAcedo-Bueno,
technology such Rodriguez-Maroto
as water leaching and Paz-
after low-
Garcia [58] presented
temperature fluorination a model
roastingforhas
thebeen
extraction
foundof lithiuminand
effective cobalt from
achieving LiCoO2purifi-
the optimal parti-
cles, which
cation of WCR considers the switchlithium-ion
from discarded in regulating mechanisms
batteries. from
Zhu, et chemical
al. [106] kinetics
applied to mass
the method
transfer.
to The model
demonstrate for lithiumprocess
a regenerative and cobalt extraction
of waste carbon from LiCoO
residue 2 particles
(WCR) satisfactorily
(Figure 10). With
reproduces
the the experimental
experimental procedure, aresults
purity in of various
99.98% for situations,
productsthereby
such ascomparing
high-purity the experi-
graphite
mental observations and simulations. Furthermore, the model
carbon (PGC) was achieved. The authors believed that this near-closed loop process wouldcan also estimate the non-
equimolartofraction
contribute of Li+
the circular and Co
economy and extracted
2+ and the
green chemistry. maximum the
Furthermore, extraction limitation
WCR purification
caused byand
technique the thecreation
yieldof inaterms
Co3Oof 4 crust
PGCsurrounding
showed a low-cost the particle’s core.
and environmentally-friendly
Using
solution organic
to treat WCR solvent
from Cyanex 272 (containing
waste lithium-ion tributyl
batteries. phosphate
A similar typeand kerosene),
of study Lu,
was per-
Stevensby
formed and Mumford
Schwich, [51] showed
Schubert the application
and Friedrich [52] usingof aasolvent extraction
combination of H2technology
O-leachingfromand
synthetic leach
carbonation solutions
treatment withforsupercritical
lithium-ion CO recovery. The on
2 , focusing experimental processThe
lithium recovery. found that
authors
pH, extractant concentration, and multivalent metal concentration had the highest impact.
investigated the Early-Stage Recovery of Lithium (ESLR) process through Supercritical
On the other hand,
CO-Carbonation. temperature,
The temperature ionic
andstrength,
holding time monovalent
were themetals (Na(I)),indicators
two leading and modifierfor
◦ C, and the
concentration
the had a lowThe
optimized condition. impact
idealon the process
thermal treatment performance.
temperature Furthermore,
for Li is 650 the authors
optimal
showeds/l thatratio
withis the
10 mL/g,
one-step according
processto the maximum
illustrated, otherreported
cathodicleaching
materialsefficiency
(e.g., Co,ofNi)
85
percent. Furthermore, indirect carbonation is demonstrated when
could be recovered with the same solvent. Chernyaev, Partinen, Klemettinen, Wilson, a dry autoclave method
is comparedand
Jokilaakso to aLundstrom
liquid-based [69]autoclave procedure.
utilized response surface modeling by considering the acid
consumption rate, Co extraction, and final acid concentration to generate a regression
equation that would allow the Cu extraction process to be optimized. The authors
Another important development in the leaching process is leaching with supercritical
CO2. For example, Pavon, Kaiser, Mende and Bertau [90] developed a process (called the
COOL process with CO2-leaching) for producing Li2CO3 from lithium-containing ores
such as zinnwaldite and spodumene. This method has recovered Li from both primary
and secondary source materials. This achievement is critical in preserving the European
Recycling 2022, 7, 33 24 of 40
industry’s raw material base for LIB manufacturing. At 230 °C for 4 h in water, a black
mass ratio of 90 mL/g and a maximum Li yield of 94.5 wt.% was achieved.
WCR
Roasted
Roasting Millied Roasted slag
sample
NH4F
Exhaust gas
NH3H2O
Filtration Precipitation
MxOy Filtration
PGC
Electrochemica
l performance
Figure 10.
Figure 10. Flow
Flow diagram
diagram of
of high-purity
high-purity graphite
graphite carbon
carbon and
and metal
metal recovery
recovery from
from WCR,
WCR, redrawn
redrawn
from Zhu, Xiao, Mao, Zhang, You, Tang and Zhong [106].
from Zhu, Xiao, Mao, Zhang, You, Tang and Zhong [106].
3.2.3.Another
Pyrometallurgical Process
important development in the leaching process is leaching with supercritical
CO2 .Ruismaki, Rinne,
For example, Danczak,
Pavon, Kaiser,Taskinen,
Mende andSerna-Guerrero and Jokilaakso
Bertau [90] developed [59] performed
a process (called the
a laboratory-scale flotation
COOL process with CO 2 experiment to integrate industrial
-leaching) for producing Li2 CO 3 nickel slag cleaning andores
from lithium-containing re-
cycling LIBs. They concluded that graphite in the flotation fractionLi
such as zinnwaldite and spodumene. This method has recovered could
fromreplace coke in
both primary
the nickel
and slag cleaning.
secondary Furthermore,
source materials. This the authors found
achievement that, in terms
is critical of time—0–1
preserving min—
the European
industry’s raw material base for LIB manufacturing. At 230 ◦ C for 4 h in water, a black
mass ratio of 90 mL/g and a maximum Li yield of 94.5 wt.% was achieved.
from LIBs. Sommerfeld, Vonderstein, Dertmann, Klimko, Orac, Miskufova, Havlik and
Friedrich [85] investigated a suitable slag design containing lithium and other metals such
as cobalt, nickel, and copper alloy (as byproducts of the process) using a laboratory electric
arc furnace. The authors mentioned that a considerable number of metals were lost as flue
dust, which should be recirculated for better recovery yield.
Figure
Figure 11.11. Cathode-Healing Direct
Cathode-Healing Direct recycling
recyclingtechnology for for
technology spent LIBsLIBs
spent by OnTo Technology
by OnTo (USA), (USA),
Technology
adapted
adapted from
from [107].
[107].
Castro,
Castro, Cutaiaand
Cutaia andVaccari
Vaccari[101]
[101] saw
saw direct
directrecycling
recyclingasasanan incentive
incentiveto risk the the
to risk sup-supply
ply chain of automobile LIBs due to a significant lack of materials. On the
chain of automobile LIBs due to a significant lack of materials. On the other hand, Azadnia, other hand,
Azadnia, Onofrei and Ghadimi [53] noted that direct recycling has high manufacturing
Onofrei and Ghadimi [53] noted that direct recycling has high manufacturing costs and
costs and process complexity. Regardless of the cost structure of this method’s processing,
process complexity. Regardless of the cost structure of this method’s processing, the
the primary benefit is that less chemical application is often required [54]. Direct recycling,
primary benefit is that less chemical application is often required [54]. Direct recycling,
often known as short-loop recycling, refers to the reuse of active materials without return-
often
ing to theiras
known short-loop
component recycling,
metals refers
or salts [86].to the the
After reuse of activesteps,
separation materials without ma-
the recovered returning
to their component metals or salts [86]. After the separation steps, the
terials (mainly the extraction of cathode and anode materials) may be reused and recon- recovered materials
(mainly thefor
ditioned extraction of cathode
remanufacturing [13].and anode
As the materials)
anode graphite may be reused
of wasted and reconditioned
LIBs keeps its com-
for plete layered structure
remanufacturing [13].after several
As the anode charges and of
graphite discharge
wasted cycles,
LIBs keepsdirectits
recycling
complete waslayered
used to after
structure modify the anode
several material
charges and[106]. In the procedure,
discharge cycles, directthe recycling
components was areused
separated
to modify
thefrom
anodethematerial
active substance powder
[106]. In of shredded
the procedure, cells
the (“black matter”)
components [68]. This technology
are separated from the active
is capable of lengthy and complex purification operations,
substance powder of shredded cells (“black matter”) [68]. This technology and it can recover almostis all
capable
battery constituents [13].
Physical separation procedures followed by the re-lithiation of electrode coatings and
integration into a new cell are required for direct recycling [86]. Stabilization, disassembly,
and separation are the pre-treatment processes of the separation procedures [13]. Small,
dismantled cells are treated with supercritical CO2 and electrolytes were extracted and
Recycling 2022, 7, 33 26 of 40
of lengthy and complex purification operations, and it can recover almost all battery
constituents [13].
Physical separation procedures followed by the re-lithiation of electrode coatings and
integration into a new cell are required for direct recycling [86]. Stabilization, disassembly,
and separation are the pre-treatment processes of the separation procedures [13]. Small,
dismantled cells are treated with supercritical CO2 and electrolytes were extracted and
treated in this procedure [105], which applies to all LIB chemical types [13]. Also employed
in casing and wiring recovery is supercritical CO2 [68]. Bai, Muralidharan, Li, Essehli and
Belharouak [66] demonstrated a solvent-based delamination technique for direct recycling.
The process employed ethylene glycol (EG) as the functional solvent to deactivate the
bonding between the polyvinylidene fluoride (PVDF) binder and the current collector.
This recycling technique can return crucial commodities with high demand to the supply
chain [99]. In the European Union and the United States, the technology’s economic (as a
lower-cost option) and environmental advantages, particularly for graphite recovery, have
been studied [86]. Hou, Dai, Liu, Yaol, Yu and Li [76] noted that the electrochemical Li-
storage activity of the functional group inside oxytetracycline is an essential characteristic
for the direct recycling of the anode material.
One of the most essential features of direct recycling is maintaining the purity of the
material waste streams, which requires separate processing for cell packing and component
removal [86]. Ali, Khan and Pecht [13] highlighted mechanical pre-treatment, with excellent
contamination rates for recovered materials and lower product value as shortcomings of
the recycling process. Changing battery designs, chemistries, and cathode metal oxide
compositions are other issues for recycling [54]. Gloser-Chahoud, Huster, Rosenberg, Baa-
zouzi, Kiemel, Singh, Schneider, Weeber, Miehe and Schultmann [46] focused on industrial
scale disassembly for direct physical recycling ecological efficiency. For the strategy to be
economically sustainable from a circular economy standpoint, additional data and research
are needed [99]. The state of health (SOH) of LIBs impacts recycling efficiency [13].
Recycling
LIB production PHEV use stage Repurposing
(Hydro)
Step 2: Automotive
manufacturer Recycling (pyro/
Remanufacturing
perspective hydro)
Recycling (pyro)
Time
Figure 12. Two-step process of battery second-life application for energy storage system and asso-
Figure 12. Two-step process
ciated of battery
business models [44]. second-life application for energy storage system and associ-
ated business models [44].
3.4. Analyzing Decision Making Studies
In theMaking
3.4. Analyzing Decision decision-making-related
Studies research domain, the Delphi method or technique is
widely used across disciplines. The method was first proposed for predicting the influ-
In the decision-making-related
ence of technology on conflict byresearch
Olaf Helmer domain,
and Norman the Delphi
Dalkey at the method
RAND Corpo- or technique
is widely usedration
across[108,109]. The Delphi approach
disciplines. is effective when
The method wasa research topic does notfor
first proposed lend itself
predicting the
to exact analytic tools [110]. The approach is a commonly used strategy for getting per-
influence of technology
spectives on aon conflict
subject by Olaf
that requires Helmer
immediate and
attention but Norman Dalkey
for which there at the RAND
is no infor-
mation (or consensus) available [111]. Agreement on
Corporation [108,109]. The Delphi approach is effective when a research topicthe diverse and complex topics is does not
often reached by a team of specialists in a particular subject, and the process follows a
lend itself to exact analytic tools [110]. The approach is a commonly used
methodical procedure to arrive at a consensus on certain assessment criteria [112]. Figure
strategy for
getting perspectives
13 showson a subject
a general thatprocess
step-by-step requires immediate
flow diagram attention
of the Delphi but for which there
technique.
is no information (or consensus) available [111]. Agreement on the diverse and complex
topics is often reached by a team of specialists in a particular subject, and the process
follows a methodical procedure to arrive at a consensus on certain assessment criteria [112].
Figure 13 shows a general step-by-step process flow diagram of the Delphi technique.
Using the Delphi technique, Kumar, Singh, Paul and Sinha [48] identified critical EV
battery supply chain challenges. The authors found that the most significant barrier to
the long-term sustainability of the EV battery supply chain is the inadequate recycling and
reuse of EV batteries. Supply shortages in the EV battery supply chain caused by the rapid
development of EV demand is also a critical challenge. Due to the scarcity of lithium and
cobalt resources, battery recycling may be one of the most important sources of these materials.
It will assist in safeguarding the environment and meet the growing demand for electric
vehicles, as well as keep the need for virgin materials for the LIB under control. Wralsen,
Prieto-Sandoval, Mejia-Villa, O’Born, Hellstrom and Faessler [7] adopted the Delphi study
approach to identify circular business models for wasted lithium-ion batteries and the primary
drivers, barriers, and stakeholders to consider. Battery cell and raw material manufacturers
are highly regarded due to their expertise in developing battery standards for procedures such
as better recycling. The word “remanufacture” refers to the process of reviving an EV battery
that has been abandoned and the reuse of batteries in the same application for both first
and second uses. The experts interviewed in the study suggested that professional logistics
organizations, recyclers, and manufacturers should be responsible for LIB collection because
they are key actors in the LIB supply chain and partners in circular business models. Using
the Delphi technique, a thorough list of significant barriers to the successful implementation
of reverse logistics (RL) activities for the EoL management of EVs-LIBs was found by Azadnia,
Onofrei and Ghadimi [53]. According to the authors, there is a need to provide subsidies
and assistance packages to manufacturing enterprises to help them develop their recycling
Recycling 2022, 7, 33 28 of 40
Using thePlanning
3.5. Analyzing Delphi technique,
Studies Kumar, Singh, Paul and Sinha [48] identified critical EV
battery supply chain challenges.
Baars, Domenech, Bleischwitz, TheMelin
authors
andfound that[49]
Heidrich the mentioned
most significant barrier to the
that improvements
long-term
in vehicle EOLsustainability
traceability,ofcollection
the EV battery supply
rates, and chain
battery is the
design inadequate
would recycling and
help to strengthen the
reuse of EV batteries. Supply shortages in the EV battery supply chain caused
recycling industry, assure essential material supply security, and provide incentives for the by the rapid
development
establishmentof ofEV
an EUdemand
battery is also a critical challenge.
manufacturing industry.Due Theytoalso
the concluded
scarcity of that
lithium and
policies
cobalt resources, battery recycling may be one of the most important
like extended producer responsibility are achievable and serve as catalysts for change thatsources of these ma-
terials. It will
will boost assist and
recycling in safeguarding
improve EV the environment
battery collectingandrates. meet the growing demand for
electric vehicles,Akshay
Natarajan, as well and
as keep the need[94]
Aravindan fordiscussed
virgin materials
variousfor the to
ways LIB under control.
separate current
Wralsen,
collectorsPrieto-Sandoval,
from the electrode Mejia-Villa,
materials of O’Born,
wastedHellstrom
LIBs and and Faessler
future research [7]directions
adopted thefor
Delphi study
researchers approach
seeking to identify
to develop circular
efficient business
recycling models for wasted
methodologies. In mostlithium-ion batter-
lab-scale recycling
ies and the primary
experiments, drivers,
the authors used barriers, and stakeholders
mechanical to consider.separation,
sorting, electrochemical Battery cellcryogenic
and raw
material
grinding,manufacturers
thermal treatment, are highly regarded due
low-temperature to their
molten expertise inultrasonic
salt separation, developing battery
treatments,
standards for procedures
and other methods suchcurrent
to separate as better recycling.
collectors The
from wordelectrode
active “remanufacture”
materials.refers to the
In addition,
process of reviving
the authors mentioned an that
EV battery
both anodesthat has
and been abandoned
cathodes could use and
Al the
foil reuse of batteries
as a current in
collector.
the same application
According for both
to the authors, first and
recycled second
Al foil mayuses.
be usedTheas experts interviewedsubstrate
a supercapacitor in the study
and
suggested that professional
might encourage the recycling logistics
of spentorganizations, recyclers,
LIBs in a zero-waste and manufacturers
manner should
for the industries.
be responsible for LIB collection because they are key actors in the LIB supply chain and
partners in circular business models. Using the Delphi technique, a thorough list of sig-
nificant barriers to the successful implementation of reverse logistics (RL) activities for the
EoL management of EVs-LIBs was found by Azadnia, Onofrei and Ghadimi [53].
Recycling 2022, 7, 33 29 of 40
Charles, Davies, Douglas, Hallin and Mabbett [83] assessed the potential of batteries,
such as Li-ion, Pb-acid, and Aquion aqueous hybrid ion batteries (AHIBs), for implementing
a small-scale domestic PV system in South Africa. The authors found that there are currently
no Li-ion or AHIB recycling facilities in Africa, leaving the region with little potential to
retain the material value of these batteries. Despite their lower efficiency and shorter
lifetimes, Pb-acid batteries are the best choice for sustainable small-scale household PV
systems in South Africa. In addition, they are easily accessible and inexpensive due to
domestic manufacturing. The authors found a correlation between household income and
car access; for example, 47 percent of those with severely limited car access lived in the
most connected street network areas, compared to only 28 percent of those with full car
access. After adjusting for potential individual and neighborhood confounding factors,
evidence of statistical interactions was more substantial for lower household income and
limited car availability, but not for work status or gender.
Thompson, Hyde, Hartley, Abbott, Anderson and Harper [91] conducted a techno-
economic analysis of the hydrometallurgical process of LIB recycling. They mentioned
that liberation/separation methods largely depend on the separability of the materials of
various chemistry. In LIBs, a complicated cell architecture with several cells and modules
that make up the entire pack creates barriers to disassembly and separation. The authors
also mentioned that these processes might result in less expensive procedures and produce
higher-value materials than shredding and leaching, assuming the development of efficient,
cost-effective automated disassembly systems. These improved approaches have the
potential to save more value in a circular LIB supply chain than specific current solutions
that destroy value. According to a retro-economic study, the processing costs for batteries
should be around $2–6/kg of battery to enable gate fee-free processing.
Hsieh, Pan and Green [92] mentioned that the automotive sector is predicted to be
the fastest-growing source of used LIBs over the next three decades, given the trend
towards vehicle electrification. This paper gives up-to-date information on China’s private
vehicle market size by analyzing the relative car price of plug-in electric vehicles (PEVs) to
internal combustion engine vehicles (ICEVs) and considering the evolving PEV policies.
This PEV expansion will generate roughly 420 GWh of used nickel–manganese–cobalt
(NMC)-based LIBs that will need to be recycled during the next decade. The authors also
predicted that, while cobalt supply is currently under strain, most of the mineral cost
in contemporary battery compositions is for nickel and lithium. Therefore, during the
transition to electrification, significant repercussions are expected. This research aimed to
estimate the policy implications for the private passenger car industry and the PEV-driven
battery sector.
explosion-proof containers. In addition, the scientists evaluated the impedance and capacity
of cells before and after cryogenic freezing and thawing to see if low temperatures affected
cell performance. Experiments have shown no risk of thermal runaway, meaning that LIBs
can be safely transported while cryogenically frozen. Furthermore, flash freezing does not
affect electrical performance even after five repeating cryogenic cycles (energy capacity and
impedance).
Hou, Yu, Liu, Yao, Liao, Dai and Li [72] demonstrated that a waste old loofah sponge
carbonized at 800 ◦ C for 1 h in inert N2 could be used as a promising carbon anode material
in LIBs. This provides evidence for using bio-based waste material in LIB production.
Furthermore, using waste loofah carbonized biomaterial, an initial specific discharge
capacity of about 697 mAh/g and high cycling stability even at 3000 mA/g for 5000 cycles
could be achieved, indicating the satisfactory electrochemical performance of the material.
Pack
manufacture Remanufacture Pack removal
Cell
manufacturing
Cathode
Recycling
manufacturing
Figure 14. EV battery in circular economy model, redrawn from Ahuja, Dawson and Lee [99].
Figure 14. EV battery in circular economy model, redrawn from Ahuja, Dawson and Lee [99].
Tan, Wang,
Tan, Wang, Chen,
Chen, Li,
Li, Sun,
Sun, Liu,
Liu, Yang,
Yang, Xiang,
Xiang, Sun
Sun and
and Duan
Duan [82]
[82] compared
compared elegant
elegant
structures and complicated compositions for designing recycling-oriented cathode
structures and complicated compositions for designing recycling-oriented cathode mate-
ma-
rials. The authors concluded that gradient concentration cathode materials could be used
to achieve the rational design of Ni-rich ternary cathode materials with high capacity and
stability without doping with other elements, thereby making the separation more diffi-
cult. Furthermore, they found that multi-component cathode materials can be used as raw
Recycling 2022, 7, 33 31 of 40
terials. The authors concluded that gradient concentration cathode materials could be
used to achieve the rational design of Ni-rich ternary cathode materials with high capacity
and stability without doping with other elements, thereby making the separation more
difficult. Furthermore, they found that multi-component cathode materials can be used as
raw materials to generate the precursors for the multi-component NCM or NCA cathode
materials. In that case, a co-precipitation process was required when spent LIBs were
recycled using hydrometallurgy. However, when cathode materials are recovered, the trace
elements utilized to modify the cathode materials by coating or doping are challenging to
separate using the co-precipitation process. The authors also mentioned that pyrometal-
lurgy has a high level of technical maturity as a straightforward approach for recycling
LIBs in consumer electronics, and some companies have implemented it.
The distinct patterns exhibited by RSE as a function of sieving stages provided methods for
an optimized system to be modeled, enabling fewer sieving steps with a low impact on the
final concentration of materials, as demonstrated in this proof-of-concept. This paper lays the
groundwork for including a new parameter—statistical entropy—in material processing system
analysis, design, and optimization.
green solvent use is gaining popularity. Froth flotation and organic waste use for
material recovery are gaining significant attention. Many of the experimental studies
claimed to have industrial-scale applications. Many of the processes moved towards a
zero-waste approach, showing the motivation towards a circular economy with low
process/less environmental impact.
• At present, within the articles analyzed, an EV market assessment is limited to the
USA and Europe, and, in some cases, to BRICS countries. It should be expanded
to other developed countries, such as Australia, which has the largest reserve of Li,
is a significant player in Li production, and has aggressive demand for EVs in the
coming years. However, a comprehensive global level assessment of the EV market
should be performed. There is a scope for applying the LCA model for EOL scenarios
based on the predicted automobile market globally and from regional perspectives
(developing countries, material supply countries). Specific route selection for future
EOL EV batteries requires further attention, as developing countries are not well
equipped to explore various opportunities.
• Biological process and consumer behavior-related issues were less discussed topics
associated with LIB recycling. Furthermore, most studies focused on EVs; a detailed
assessment of the spent batteries derived from electronic waste (e-waste) and other
portable equipment should be done.
• Less attention has been given to low-value non-metallic components such as solvents,
plastics, lithium salts, and phosphorus, as shown by Sommerville, Zhu, Rajaeifar,
Heidrich, Goodship and Kendrick [86]. There is a prospect of conducting a lifecycle
cost assessment (LCC) of the recovered material from spent LIBs containing metallic
and non-metallic components.
• The battery storage system is an emerging component that can be developed by reusing
and remanufacturing the usable battery cells from EVs. However, there is a need for
a comparative lifecycle assessment based on a battery energy storage system (BESS)
developed from recycled material and a system constructed using virgin materials.
There is a connection between solar PV and EV when it comes to BESS. Therefore,
more research should be carried out to understand the opportunities around providing
incentives for an integrated system (around 2nd-life applications of battery and solar
PV systems together).
• From the literature analysis, it is evident that transportation (mobility) is the primary
sector that would derive the spent LIBs from EVs. There is a supply associated with the
REEs, such as Li (which is more severe than Ni), and recycling is found to be the most
critical option related to material recovery. Techno-economic perspectives of various
recycling processes should be performed to understand the eco-friendliness and
economic benefits at the industrial scale. However, before the recycling process, reuse
is the most viable option for better financial gain and environmental impact. The direct
recycling process is a complementary process for material reuse and remanufacturing,
and that also connects to the 2nd-life applications of spent LIBs materials (both cathode
and anode materials). More research should be performed in this area to assess
financial viability.
• Gaps in Extended Producer Responsibility (EPR) in spent battery reverse logistics and
recycling should further be assessed. Appropriate policy around LIBs from EV with
low-value materials should be in place, and case-specific guidance to recyclers should
be provided. To gain eco-efficiency, cascaded use, regulations, and economic incentives
would be essential [96]. There is a need to further assess the level of subsidies and
assistance packages required for EV manufacturers to develop recycling processes,
as the lack of cost-effective technologies is still a significant barrier. Newmarket
development and incentives for new businesses dealing with recycled materials were
underprivileged. The impact of the regulation of battery 2nd-life applications also
requires further attention. Financial support to develop test bench development as
part of the R&D that is assessing remaining battery life should also be widespread.
Recycling 2022, 7, 33 34 of 40
Policymakers should focus on incentivizing high initial costs for the LIB system.
Regulation targeting 2nd-life battery use and EOL management should consider
economic incentives and environmental efficiency. The regulatory intervention of
applying various business models, such as product as service or sharing models, for
effective EOL-based management engaging stakeholders should further be explored.
With the EPR, the scope for the comparative analysis of various collection schemes
should be explored.
• New business model development remains a challenge to a stable material supply that
encourages domestic recycling. Stakeholder perceptions and motivations for imple-
menting circular business model strategies, such as regeneration, reuse, and recycling,
should be understood by empirical research from diverse country contexts, as EV
penetration is uneven across the globe (developed vs. developing countries). There is
a clear separation between circular strategies for EV LIBs—reuse and remanufacturing
(2nd-life applications) and recycling (for material recovery, for example, cost-intensive
recovery of Li, which is now limited to 50–60% at the industrial scale). There would be
a shift from battery sales to service provision (under the product as service—circular
business model). Command and control, market incentives, and regulatory design
were central to developing an innovative business model.
• Reverse logistics is one of the critical issues associated with fire safety and the efficient
recovery of materials. Flash cryogenic freezing as a method described by Grandjean,
Groenewald, McGordon and Marco [74], among other processes, could be one of the
solutions that support further research and initiatives in this area.
• Relative statistical entropy (RSE) and MFA were applied by Velazquez-Martinez, Por-
vali, van den Boogaart, Santasalo-Aarnio, Lundstrom, Reuter and Serna-Guerrero [88]
for an optimized material recovery process. Alternative methods such as exergy and
thermos–economic analysis could also be used as per the authors to understand the
Al and Cu recycling process. The authors applied the RSE method and MFA for the
individual hydrometallurgical and pyrometallurgical processes. A similar analysis
could be used for the cathode material (that contains Li and Co) recovery process or
the direct recycling process. RSE and MFA-based complex simulation methods were
also proposed by Martinez, Van den Boogaart, Lundstrom, Santasalo-Aarnio, Reuter
and Serna-Guerrero [65]. Simulation types of studies could further be extended to
applying LCA in a step-by-step process for understanding the potential environmental
impacts of various recycling processes or sub-processes, such as the sieving system.
• Due to the complexity of the present EV battery design and the requirement for future
large-scale battery pack disassembly, robot-assisted automatic disassembly will be
the next frontier in this case. A bar code application and RFID tag-based material
identification technique could be applied at the beginning of the product design so
that the disassembly process could be more efficient and effective. The application
of blockchain technology was found for various other waste streams such as fashion,
textile, and e-waste, which can also be applied to EV LIBs as this waste stream is
more material-intensive (containing high-value materials). Electrochemical impedance
spectrometry was seen as one of the large-scale disassembly techniques.
• Material substitution (anode material in LIBs) is also a critical area with ample oppor-
tunities, especially when using expired or wasted materials. For example, Dai, Hou,
Liu, Yao, Yu and Li [77] used expired aminophylline for LIB anode material. There
will be new research directions, i.e., finding alternative materials to be used in LIB
production. However, from the circular economy context, such further material use
must consider the EOL solutions simultaneously so that downstream recycling could
be performed economically and in an environmentally-friendly manner (application
of LCA would be an essential part of the assessment). With the current demand for
Ni, mining output would meet only 34% of the global market. Alternatives should
be found simultaneously, and recovery techniques should be experimented with. In
addition to recent geopolitical issues, such as the war in Ukraine, which suddenly
Recycling 2022, 7, 33 35 of 40
forced the price of Ni to be significantly higher, again indicates the market volatility
around metal prices and required increased attention to cathode material recycling—as
well as finding alternative materials and product designs for batteries. From February
2022 to April 2022, the price of Ni increased from $24,361 to $33,223 per tonne, which
was a sudden shock for EV manufacturing industries [114].
• LIB repurposing as part of the CBM development is an open research opportunity
integrating several assessment methods such as LCA and energy flow modeling, as
observed from the literature. The combination of MFA and LCA should be explored
to understand the economic viability of high-value material recovery. Coordination
between EV manufacturers and energy storage system suppliers should be explored
for energy system development from repurposed EV batteries. The environmental
and economic impacts of the regeneration of the battery manufacturing system (using
recycled material) should be assessed compared to new raw material usage (virgin
material from mining) by using cradle-to-cradle LCA models. Remanufacturing and
2nd-life applications of LIBs should be further assessed using various indicators
of CBM elements—such as value proposition, value creation, and value capture.
Stakeholders’ intention and their concerns should clearly be articulated through in-
depth research.
• The hydrometallurgical process will dominate in terms of the amount of material
recovery and process cost. The battery cell design is critical for high yield in the down-
stream recycling process. Further assessment of the system-level development for a
range of EV batteries (configuration and chemistries) should be identified. Product
design should be performed so that cathode materials can be easily recycled and
repurposed. Tan, Wang, Chen, Li, Sun, Liu, Yang, Xiang, Sun and Duan [82] have
given some examples for future research, such as understanding failure mechanisms,
cathode material with a single structure, material design, and material upgrading. A
combined hydro- and pyrometallurgical recycling process scheme could be modeled
by understanding the overall environmental impact of the integrated process. The
integration would be necessary to minimize the material loss that is generally the case
for the pyrometallurgical process (materials such as REEEs, Li, and Mn are lost in slag)
when the mixed battery (NiMH plus LIBs) is recycled.
• The recycling process should be given more attention from the point of view of material
supply risk. Furthermore, when material recovery is considered from recycling, an
environmental impact assessment of virgin material should be performed to realize
the net benefits of a recycling plant’s high investment and operational cost (i.e., cost of
electricity).
• Despite intensive research on the LIB recycling process, the characteristics of other al-
ternatives, such as the reuse and remanufacturing of batteries, are generally unknown
when assessing the remaining life. The optimization of single methods and lifecycle
stages should be given further attention. The remaining lifetime assessment of used
batteries and durability should be based on more scientific data (battery characteri-
zation). Such an assessment method should support the decision-making process in
selecting the routes for 2nd-life applications of batteries.
• Second-life application delays close-loop recycling. However, this application should
not be expected by the recyclers. In this scenario, EOL management (including the
2nd-life application) should involve recyclers so that after the remaining 2nd life, they
receive a stable supply of waste material. That means that stakeholders associated
with 2nd-life applications (such as energy storage systems) would work closely with
recyclers by exchanging data and information. Collaboration in the battery value chain
is essential, as Olsson, Fallahi, Schnurr, Diener and van Loon [15] identified for new
business opportunities and models.
Recycling 2022, 7, 33 36 of 40
5. Conclusions
This article reviewed 93 articles on LIB recycling and circular economy-related aspects.
The trend in this research domain is exponentially increasing, focusing on the experimental
recycling process to increase the material recovery rate. The pre-treatment process for mate-
rial recovery with a subsequent application of the direct physical recycling method could be
an economically viable process solely for remanufacturing and reusing the cell components
for new cell manufacturing. However, critical barriers, such as the heterogeneity of the
cell design and battery chemistries, must be overcome to see these opportunities. The
hydrometallurgy process remains the most acceptable method for metal recovery; however,
bio-based solvent and reagent use is progressing slowly, which is a positive sign. For a
circular economy, the recycling process must be economically viable and environmentally
friendly. LCA-related schemes must be employed as part of the experimental success.
Reverse logistics and collaboration among stakeholders creating new business models
(such as product as service) could provide new opportunities that ensure an efficient ma-
terial return to manufacturers and the practical implementation of an extended producer
responsibility scheme in the LIBs value chain. EV manufacturers have a critical role to play
in the battery value chain. Besides, establishing recycling plants and financial and R&D
support to universities/researchers and startups should be given for new battery product
designs using renewable (alternative) materials, and with a specific focus on middle and
end-of-life scenarios so that products can adhere to the principles of the circular economy.
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