Direct recycling industrialization of Li-ion batteries: The pre-processing barricade

Abstract

The substantial amount of retiring Li-ion batteries (LIBs) is a reason for environmental concern but also an economic opportunity. Extracted materials by recycling these batteries can potentially help coping with the rising demand and supply chain issues. Direct recycling is the most effective and economic way to reinsert the valuable cathode into cell manufacturing. Feedstock retrieval for direct recycling from the end-of-life (EoL) LIBs will be critical to validate scaling. Pre-processing constitutes the initial stage of safe and efficient handling of LIBs in the pursuit of feedstock retrieval. Here we have discussed the pre-processing steps for cathode black mass (CBM) extraction from EoL LIBs suitable for direct recycling feedstock. Pre-processing steps and their relevance to avoid impurities originating from cell components while maintaining active material features has been reviewed. We have attempted to understand the impact of impurity elements, such as Al, Cu, F, and C, on the active material direct regeneration from existing literature. Reviewing current state of the art for the pre-processing and direct recycling technologies, we have estimated the prospects remaining in active material revitalization and technical barricades to its remunerative scalability.