Lithium-ion batteries (LIBs) are currently one of the most important electrochemical energy storage devices, powering electronic mobile devices and electric vehicles alike. However, there is a remarkable difference between their rate of production and rate of recycling. At the end of their lifecycle, only a limited number of LIBs undergo any recycling treatment, with the majority go to landfills or being hoarded in households. Further losses of LIB components occur because the the state-of-the-art LIB recycling processes are limited to components with high economic value, e.g., Co, Cu, Fe, and Al. With the increasing popularity of concepts such as “circular economy” (CE), new LIB recycling systems have been proposed that target a wider spectrum of compounds, thus reducing the environmental impact associated with LIB production. This review work presents a discussion of the current practices and some of the most promising emerging technologies for recycling LIBs. While other authoritative reviews have focused on the description of recycling processes, the aim of the present was is to offer an analysis of recycling technologies from a CE perspective. Consequently, the discussion is based on the ability of each technology to recover every component in LIBs. The gathered data depicted a direct relationship between process complexity and the variety and usability of the recovered fractions. Indeed, only processes employing a combination of mechanical processing, and hydro- and pyrometallurgical steps seemed able to obtain materials suitable for LIB (re)manufacture. On the other hand, processes relying on pyrometallurgical steps are robust, but only capable of recovering metallic components.

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The principle of the circular economy is to reintroduce end-of-life materials back into the economic cycle. While reintroduction processes, for example, recycling or refurbishing, undoubtedly support this objective, they inevitably present material losses or generation of undesired by-products. Balancing losses and recoveries into a single and logical assessment has now become a major concern. The present work broadens the use of relative statistical entropy and material flow analysis to assess the recycling processes of two lithium-ion batteries previously published in the literature. Process simulation software, that is, HSC Sim®, was employed to evaluate with a high level of accuracy the performance of such recycling processes. Hereby, this methodology introduces an entropic association between the quality of final recoveries and the pre-processing stages, that is, shredding, grinding, and separation, by a parameter based on information theory. The results demonstrate that the pre-processing stages have a significant impact on the entropy value obtained at the final stages, reflecting the losses of materials into waste and side streams. In this manner, it is demonstrated how a pre-processing system capable of separating a wider number of components is advantageous, even when the final quality of refined products in two different processes is comparable. Additionally, it is possible to observe where the process becomes redundant, that is, where processing of material does not result in a significant concentration in order to take corrective actions on the process. The present work demonstrates how material flow analysis combined with statistical entropy can be used as a parameter upon which the performance of multiple recycling processes can be objectively compared from a material-centric perspective.

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