Recycling and Reuse of End-of-Life Lithium-Ion Batteries: Challenges and Strategies–2nd Edition

A special issue of Batteries (ISSN 2313-0105). This special issue belongs to the section "Battery Processing, Manufacturing and Recycling".

Deadline for manuscript submissions: 25 June 2025 | Viewed by 2455

Special Issue Editors


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Guest Editor
Department of Materials Science, University of Milano-Bicocca, Via Roberto Cozzi, 55, 20125 Milano, Italy
Interests: lithium- and sodium-ion battery materials; lithium-ion battery recycling; energy storage materials and devices
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Special Issue Information

Dear Colleagues,

Lithium-ion batteries (LIBs) are electrochemical energy storage devices that have revolutionized our daily life since their commercialization, enabling the diffusion of portable devices and boosting the electric vehicle market. Associated with their widespread application in several sectors, the inevitable consequence is an ever-growing volume of end-of-life lithium-ion batteries, which poses urgent challenges for the proper management of waste. Indeed, LIBs are complex and compact objects, containing a wide range of different materials (metal foils and wires, plastic cases and separators, oxide powders, organic solvents, salts, etc.). Moreover, the essential components of the batteries contain valuable critical raw materials, such as lithium, cobalt, and nickel; the recovery of such elements has the potential to form the basis of a beneficial circular economy scheme. Today, the available industrial technologies for LIB recycling are not able to satisfy the requirements for environmental sustainability and do not allow for the recovery of all the valuable elements; efforts are needed to identify new solutions in the complex sequence of steps following the disposal of waste LIBs, including proper sorting, discharging, dismantling, reuse, or recycling.

In this Special Issue, we present contributions addressing, but not limited to, these major topics: defining protocols and strategies, highlighting challenges, and identifying possible routes for the management of the various aspects involved in the recycling and reuse of lithium-ion batteries. The wide spectrum of topics and approaches considered here is necessary to fully address such a complex challenge.

  • Protocols for pre-treatments, cell discharge, and cell disassembly at laboratory and industrial scale;
  • Protocols for the robust and fast analysis of the state of health and charge of the battery;
  • Processes and materials for the degradation of battery components (cathode, anode, electrolytes, and current collectors);
  • Processes and materials for the recovery of critical/strategic raw materials through the isolation of target elements via separation, precipitation, and filtration;
  • The upcycling and recycling of different components of waste lithium-ion batteries (cathode, anode, electrolytes, and current collectors);
  • The regeneration and healing of degraded battery components (cathode, anode, electrolytes, and current collectors) for their direct recycling;
  • Assessment of the environmental and economical sustainability of all the above-mentioned aspects;
  • New perspectives on the development of new-generation lithium-ion battery materials and designs to enable easy recycling.

Prof. Dr. Elza Bontempi
Dr. Chiara Ferrara
Guest Editors

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Keywords

  • end-of-life lithium-ion batteries
  • recycling
  • critical and strategic raw materials
  • second life
  • circular economy
  • sustainability

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Related Special Issue

Published Papers (3 papers)

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Research

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17 pages, 6090 KiB  
Article
Optimising the Selective Leaching and Recovery of Cobalt, Lanthanum, and Strontium for Recycling End-of-Life Solid Oxide Cells
by Martina Bruno, Sofia Saffirio, Federico Smeacetto, Sonia Fiorilli and Silvia Fiore
Batteries 2025, 11(4), 124; https://doi.org/10.3390/batteries11040124 - 25 Mar 2025
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Abstract
This study explored the selective recovery of Co, La, and Sr from end-of-life solid oxide cells (SOCs) using ultrasound-assisted leaching in HCl. HCl concentration (1, 5, and 10 M) and solid-to-liquid ratio (S/L, 100 and 200 g/L) were varied to optimize the efficiency [...] Read more.
This study explored the selective recovery of Co, La, and Sr from end-of-life solid oxide cells (SOCs) using ultrasound-assisted leaching in HCl. HCl concentration (1, 5, and 10 M) and solid-to-liquid ratio (S/L, 100 and 200 g/L) were varied to optimize the efficiency and the selectivity of Co, La, and Sr leaching. Then, they were recovered as oxalates at pH 0.7, 1, and 4. Using 10 M HCl and an S/L ratio of 100 g/L on ball-milled samples achieved 96–99% leaching efficiency but led to Ni impurities from the underneath layers. Thermal pre-treatment at 800 °C decreased Ni leaching by 90% but decreased target metals’ recovery by 9%. Direct leaching (without pre-treatments) with 1 M HCl and an S/L ratio of 200 g/L achieved up to 91% leaching efficiency, recovering 42% of Co, 93% of La, and 33% of Sr with minimal Ni impurities. A preliminary economic analysis indicated that avoiding pre-treatments can cut expenses by 96%. An economic analysis indicated that direct leaching is the most cost effective, reducing expenses by up to 96% compared to thermal pre-treatment and high HCl concentrations. This study highlights the potential for an efficient and cost-effective method for recycling Co, La, and Sr from EoL SOCs. Full article
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13 pages, 6626 KiB  
Article
Exploring the Solubility of Ethylene Carbonate in Supercritical Carbon Dioxide: A Pathway for Sustainable Electrolyte Recycling from Li-Ion Batteries
by Nils Zachmann, Claude Cicconardi and Burçak Ebin
Batteries 2025, 11(3), 98; https://doi.org/10.3390/batteries11030098 - 4 Mar 2025
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Abstract
Ethylene carbonate is, among other applications, used in Li-ion batteries as an electrolyte solvent to dissociate Li-salt. Supercritical CO2 extraction is a promising method for the recycling of electrolyte solvents from spent batteries. To design an extraction process, knowledge of the solute [...] Read more.
Ethylene carbonate is, among other applications, used in Li-ion batteries as an electrolyte solvent to dissociate Li-salt. Supercritical CO2 extraction is a promising method for the recycling of electrolyte solvents from spent batteries. To design an extraction process, knowledge of the solute solubility is essential. In this work, the solubility of ethylene carbonate at different pressure (80–160 bar) and temperature (40 °C, and 60 °C) conditions is studied. It is shown that the solubility of ethylene carbonate increased with pressure at both temperatures, ranging from 0.24 to 8.35 g/kg CO2. The retrieved solubility data were fitted using the Chrastil model, and the average equilibrium association number was determined to be 4.46 and 4.02 at 40 °C and 60 °C, respectively. Scanning electron microscopy, Fourier-transform infrared spectroscopy, and X-ray diffraction analysis of the collected ethylene carbonate indicated that the crystal morphology and structure remained unchanged. A proof-of-principle experiment showed that EC can be successfully extracted from Li-ion battery waste at 140 bar and 40 °C. Full article
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Review

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23 pages, 3771 KiB  
Review
The Sustainable and Green Management of Spent Lithium-Ion Batteries Through Hydroxy Acid Recycling and Direct Regeneration of Active Positive Electrode Material: A Review
by Ambar B. Shrestha and Ananda S. Amarasekara
Batteries 2025, 11(2), 68; https://doi.org/10.3390/batteries11020068 - 8 Feb 2025
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Abstract
The rapid increase in use of lithium-ion batteries in energy storage together with limited supply of critical metals used in batteries and environmental concerns have led to the urgent need for sustainable recycling technologies for these batteries. Li-ion battery chemistry, components, various designs, [...] Read more.
The rapid increase in use of lithium-ion batteries in energy storage together with limited supply of critical metals used in batteries and environmental concerns have led to the urgent need for sustainable recycling technologies for these batteries. Li-ion battery chemistry, components, various designs, and two main approaches for recycling: pyrolysis and hydrometallurgical techniques are discussed in this review focusing on the novel, sustainable green approach of hydroxy acid leaching followed by a direct regeneration technique. This two-step emerging technique is compared with other conventional recycling methods in this critical review emphasizing simplicity and commercial potential. Current literature reporting rapid developments on this scalable process with pretreatment phases of sorting, discharging, disassembly of batteries, separation of electrode coatings from current collectors, leaching black mass with hydroxy carboxylic acids, separation of graphite, adjustments of Li, Ni, Mn, and Co compositions, and regeneration via co-precipitation or sol–gel formation techniques followed by pyrolysis are discussed in the detailed review. The conclusion section of this direct regeneration focused critical review gives an insight into challenges in hydroxy acid recycling and direct regeneration technology and practical solutions that may help in development into a mainstream technology. Full article
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