Circular ecosystem vital for better EV recycling

Published in Nature Reviews Clean Technology, the research examined the current state of lithium-ion battery (LIB) recycling, looking at existing industrial as well as developing technologies. It found that to replace energy and resource intensive practices such as pyrometallurgy and hydrometallurgy to separate battery materials, approaches such as direct recycling and upcycling could be adopted, bringing significant cost and efficiency gains.

According to the study, these changes could cut costs by up to 40 per cent while also minimising secondary pollution. However, the shift would require a leap in collaboration across the entire EV value chain, from vehicle OEMs and battery manufacturers to recyclers and regulators.

"The rapid growth in electric vehicle adoption demands urgent action to create a sustainable circular economy for lithium-ion batteries” said study co-author Dr Gavin Harper, from Birmingham University’s School of Metallurgy and Materials.

“Over 17 million electric vehicles were sold globally in 2024. By investing in advanced recycling technologies and fostering collaboration across industries, we can significantly reduce environmental impacts while ensuring that LIB recycling keeps pace with market demands.”

The research, which featured contributions from engineers at Worcester Polytechnic Institute (WPI) and Massachusetts Institute of Technology (MIT), resulted in a list of recommendations to enhance the efficiency, sustainability, and scalability of LIB recycling technologies. These included redesigning LIBs for easier disassembly, scaling up direct recycling to preserve material functionality, building partnerships across the ecosystem, and standardising protocols to manage end-of-life batteries more effectively.

The work also explored how emerging technologies such as bioleaching, deep eutectic solvents (DES), and robotic disassembly could transform the recycling landscape.

“The scope of materials recovered from spent lithium-ion batteries is broadening,” said study co-author Professor Yan Wang, from WIP’s Mechanical and Materials Engineering Department.  

“While traditional methods focus on cathode materials, newer techniques are extending to anode materials, electrolytes, binders, separators, and current collectors.”