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The transition to electric mobility is crucial for reducing transportation-related emissions and shifting to renewable energy sources. Lithium-ion batteries dominate energy storage for electric vehicles and stationary applications, but sustainability concerns persist due to the reliance on critical raw materials like lithium, nickel, and cobalt. New gellified battery cells incorporate advanced materials, such as gellified electrodes and high-voltage gel electrolytes, aiming for higher energy densities of 350–400 Wh/kg and cathode potentials up to 4.9 V. However, conventional lithium-ion battery recycling methods—pyrometallurgy, hydrometallurgy, and direct recycling—must be adapted for these cells. In gellified cells, active materials and electrolytes are trapped in a PVDF gel, requiring specialized pretreatment before standard recycling processes can be applied. Effective battery recycling reduces dependence on virgin material extraction, mitigates environmental harm, and supports the European Commission’s goal of recycling 65% of lithium-based batteries by 2025. Studies show that environmental impacts from battery production can be significantly lowered through optimized recycling methods. This research explores an innovative recycling process for 3B battery technology - gellified battery cells, and assesses its environmental impact through Life Cycle Assessment. By comparing this method to virgin material extraction, the study highlights the sustainability benefits of new recycling concepts. Addressing current gaps in gellified cell recycling, this research contributes to advancing battery sustainability and minimizing environmental impact in future energy storage solutions. The proposed recycling process demonstrates high recovery efficiencies, achieving 76.9% for lithium, 76.7% for manganese, and 76.5% for nickel. This advancement significantly mitigates the environmental impacts associated with the extraction of virgin materials and underscores the vital importance of recycling in enhancing battery sustainability.

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Increasing Environmental Performance of Battery Technologies: Recycling as Key for Minimizing Critical Raw Material Mining

  • 会议论文

  • 发表日期：

    2026年

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  • Maria Soares,
  • Emanuel J. Lourenço,
  • Nanna Bjerre-Christensen,
  • Thomas Opsomer,
  • Sara M. Pinto

摘要

The transition to electric mobility is crucial for reducing transportation-related emissions and shifting to renewable energy sources. Lithium-ion batteries dominate energy storage for electric vehicles and stationary applications, but sustainability concerns persist due to the reliance on critical raw materials like lithium, nickel, and cobalt. New gellified battery cells incorporate advanced materials, such as gellified electrodes and high-voltage gel electrolytes, aiming for higher energy densities of 350–400 Wh/kg and cathode potentials up to 4.9 V. However, conventional lithium-ion battery recycling methods—pyrometallurgy, hydrometallurgy, and direct recycling—must be adapted for these cells. In gellified cells, active materials and electrolytes are trapped in a PVDF gel, requiring specialized pretreatment before standard recycling processes can be applied. Effective battery recycling reduces dependence on virgin material extraction, mitigates environmental harm, and supports the European Commission’s goal of recycling 65% of lithium-based batteries by 2025. Studies show that environmental impacts from battery production can be significantly lowered through optimized recycling methods. This research explores an innovative recycling process for 3B battery technology - gellified battery cells, and assesses its environmental impact through Life Cycle Assessment. By comparing this method to virgin material extraction, the study highlights the sustainability benefits of new recycling concepts. Addressing current gaps in gellified cell recycling, this research contributes to advancing battery sustainability and minimizing environmental impact in future energy storage solutions. The proposed recycling process demonstrates high recovery efficiencies, achieving 76.9% for lithium, 76.7% for manganese, and 76.5% for nickel. This advancement significantly mitigates the environmental impacts associated with the extraction of virgin materials and underscores the vital importance of recycling in enhancing battery sustainability.