Research for the recycling of lithium-ion batteries (LIBs) started about 15 years ago. In recent years, several processes have been realized in small-scale industrial plants in Europe, which can be classified into two major process routes. The first one combines pyrometallurgy with subsequent hydrometallurgy, while the second one combines mechanical processing, often after thermal pre-treatment, with metallurgical processing. Both process routes have a series of advantages and disadvantages with respect to legislative and health, safety and environmental requirements, possible recovery rates of the components, process robustness, and economic factors. This review critically discusses the current status of development, focusing on the metallurgical processing of LIB modules and cells. Although the main metallurgical process routes are defined, some issues remain unsolved. Most process routes achieve high yields for the valuable metals cobalt, copper, and nickel. In comparison, lithium is only recovered in few processes and with a lower yield, albeit a high economic value. The recovery of the low value components graphite, manganese, and electrolyte solvents is technically feasible but economically challenging. The handling of organic and halogenic components causes technical difficulties and high costs in all process routes. Therefore, further improvements need to be achieved to close the LIB loop before high amounts of LIB scrap return.
The introduction of electromobility causes major challenges as new components and materials enter vehicle recycling. This paper discusses the current developments in the recycling of traction batteries, electric motors, and power electronics, which constitute the key components of (hybrid) electric vehicles. Both technical and ecological aspects are addressed. Beside base metals, all components contain metals that are considered critical by the EU (European Union), e.g., rare earth elements, cobalt, antimony, and palladium. As electromobility is a new trend, no recycling routes have been established at an industrial scale for these components. The implementation is complicated by small return flows and a great variety of vehicle concepts as well as components. Furthermore, drastic changes regarding design and material compositions can be expected over the next decades. Due to hazards and high weights, there is a strong research emphasis on battery recycling. Most pilot-scale or semi-industrial processes focus on the recovery of cobalt, nickel, and copper due to their high value. Electric motors and power electronics can be fed into established recycling routes if they are extracted from the vehicle before shredding.
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