Recycling and Circularity of Li-Ion Batteries

Overview

The paper frames a circular model of mining, manufacturing, use, reuse/second life, collection, recycling and disposal. Global Li-ion demand is put at about 700 GWh in 2022 rising to about 4700 GWh by 2030, and recycling revenue at 2.55 B USD (2022) to 13-18 B USD (2030). Recycling feedstock is given as 250 kt (2020), 2,000 kt (2030) and 20,500 kt (2040), with retiring batteries rising from 52% to 94% of it.

Fifteen challenges are grouped under circularity, reverse logistics, workforce safety and recovery yields. Pyrolysis pretreatment runs at about 600 deg C; pyrometallurgy smelts at up to about 1450 deg C with yields of about 32-50%; hydrometallurgy is low-energy with about 95% yield but water-intensive. Li-ion batteries are UN Class 9 dangerous goods, so transport is strictly regulated and costly.

Recycling saves about 0.7 t CO2-eq per tonne of battery, excluding lithium recovery gains (pyrometallurgical route). Second-life batteries can cost 30 to 70% less than first-life batteries for ESS applications. European collection rates are reported at 25% (2012) and 45% (2016), with a 65% target for 2025.

On policy, the EU Battery Regulation sets recycled-content minimums: 2031 cobalt 16%, lead 85%, lithium 6%, nickel 6%; 2036 cobalt 26%, lead 85%, lithium 12%, nickel 15%. Battery passports and extended producer responsibility are summarised, and circular-design principles include bolted modules and clear chemistry labelling.

Key points

1. Recycling saves about 0.7 t CO2-eq per tonne of battery (excluding lithium recovery, pyrometallurgical route).
2. Second-life batteries can cost 30-70% less than first-life ones for ESS.
3. Global Li-ion demand about 700 GWh (2022) to about 4700 GWh (2030).
4. Recycling feedstock 250 kt (2020), 2,000 kt (2030), 20,500 kt (2040).
5. EU minimum recycled content 2031: cobalt 16%, lead 85%, lithium 6%, nickel 6%; 2036: 26%, 85%, 12%, 15%.
6. Li-ion batteries are UN Class 9 dangerous goods.
7. Pyrometallurgy yield about 32-50%; hydrometallurgy about 95% but water-intensive.
8. European collection rate 25% (2012), 45% (2016); 65% target for 2025.

Using it in design

• Add chemistry (LFP/NMC/NCA), module construction (bolted or welded), battery passport availability, take-back/EPR programme and declared recycled content to the battery catalog.
• For EU projects, flag products against the Regulation (EU) 2023/1542 recycled-content milestones of 2031 and 2036.
• Include an end-of-life plan for UPS batteries in the sustainability report, using 0.7 t CO2e per tonne only as an indicative avoided-emissions figure.
• Put UN Class 9 shipping into replacement and decommissioning O&M costs, and model second-life batteries with an unclear-liability warning.

Who should read it

Teams planning end-of-life and sustainability obligations for UPS and BESS batteries.

Related standards

• Regulation (EU) 2023/1542
• UN 38.3
• IEC 62619

Publication details

Authors

Maria A. Torres Arango

Publisher

Schneider Electric

Year

2024

Document number

WP 162

Document language

English

Source type

Manufacturer

Access

Free to read

Licence

Copyright retained; citation only — the publisher’s terms apply to the original document

Citation