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DOE OSTI · 3000484

Review on Preprocessing Strategies, Deactivation, Thermal Safety, and Future Perspectives in Lithium-Ion Battery Recycling

Zhan, Zhonghua [Reaction Engineering International, Midvale, UT (United States)] (ORCID:0000000290949046)·Li, Xiaolong [Reaction Engineering International, Midvale, UT (United States)] (ORCID:0000000217082298)·Roy, Rajarshi [Reaction Engineering International, Midvale, UT (United States)]·Cremer, Marc [Reaction Engineering International, Midvale, UT (United States)]·Chiodo, Andrew [Reaction Engineering International, Midvale, UT (United States)] (ORCID:0000000321510483)·Hui, Chao [American Battery Factory, American Fork, UT (United States)]·Deng, Sili [Massachusetts Institute of Technology, Cambridge, MA (United States)] (ORCID:0000000234217414)·Keisar, David [Massachusetts Institute of Technology, Cambridge, MA (United States)] (ORCID:0000000323337397)·Fry, Andrew [Brigham Young University, Provo, UT (United States)] (ORCID:0000000241729266)·Lillie, Brooke [Brigham Young University, Provo, UT (United States)]·Nichols, McKenna [Brigham Young University, Provo, UT (United States)]·Fernando, Austine [Brigham Young University, Provo, UT (United States)]·LaTour, Parker [Brigham Young University, Provo, UT (United States)]·Alderson, Kayden [Utah San Rafael Energy Laboratory, Orangeville, UT (United States)]·Pearson, Jeremy [Utah San Rafael Energy Laboratory, Orangeville, UT (United States)]·Hortin, Tyler [Lion Energy, American Fork, UT (United States)]·Wendt, Jost [University of Utah, Salt Lake City, UT (United States)]
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Abstract

The rapid growth in the use of lithium-ion batteries (LIBs) in electric vehicles, consumer electronics, and renewable energy storage has made effective end-of-life management essential. Recycling LIBs is critical not only for resource recovery and environmental protection but also for ensuring safety and economic viability. This review focuses on the preprocessing technologies that precede typical recovery processes, including disassembly, sorting, discharging, electrolyte removal, dismantling, thermal treatment, separation, and flotation. These steps play a foundational role in determining the efficiency, safety, and environmental impact of LIB recycling. LIBs pose substantial fire and explosion risks due to residual charge, flammable electrolytes, and reactive materials. The conditions and successive progression of the exothermic reactions which lead to thermal runaway has been discussed. It also explores secure deactivation techniques such as external circuit discharge, saline immersion, and thermomechanical methods, alongside fire prevention strategies including the use of flame retardants, elimination of oxidants, and reduction of heat generation and accumulation. Challenges and future directions are outlined, highlighting the need for standardized designs, automation, and safer, more sustainable recycling infrastructure. Furthermore, this review is distinguished by its focused analysis of preprocessing and deactivation steps, with particular attention to the thermal safety engineering aspects of LIB recycling.

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Battery deactivationElectrodesElectrolytesLithium-ion batteryPreprocessingRecyclingRedox reactionsThermal safety

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Zhan, Zhonghua [Reaction Engineering International, Midvale, UT (United States)] (ORCID:0000000290949046), Li, Xiaolong [Reaction Engineering International, Midvale, UT (United States)] (ORCID:0000000217082298), Roy, Rajarshi [Reaction Engineering International, Midvale, UT (United States)], Cremer, Marc [Reaction Engineering International, Midvale, UT (United States)], Chiodo, Andrew [Reaction Engineering International, Midvale, UT (United States)] (ORCID:0000000321510483), Hui, Chao [American Battery Factory, American Fork, UT (United States)], Deng, Sili [Massachusetts Institute of Technology, Cambridge, MA (United States)] (ORCID:0000000234217414), Keisar, David [Massachusetts Institute of Technology, Cambridge, MA (United States)] (ORCID:0000000323337397), Fry, Andrew [Brigham Young University, Provo, UT (United States)] (ORCID:0000000241729266), Lillie, Brooke [Brigham Young University, Provo, UT (United States)], Nichols, McKenna [Brigham Young University, Provo, UT (United States)], Fernando, Austine [Brigham Young University, Provo, UT (United States)], LaTour, Parker [Brigham Young University, Provo, UT (United States)], Alderson, Kayden [Utah San Rafael Energy Laboratory, Orangeville, UT (United States)], Pearson, Jeremy [Utah San Rafael Energy Laboratory, Orangeville, UT (United States)], Hortin, Tyler [Lion Energy, American Fork, UT (United States)], Wendt, Jost [University of Utah, Salt Lake City, UT (United States)]. 2025-10-03. Review on Preprocessing Strategies, Deactivation, Thermal Safety, and Future Perspectives in Lithium-Ion Battery Recycling. https://doi.org/10.1021/acs.energyfuels.5c04050

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Lithium-ion batteries materialBattery deactivation subjectElectrodes subjectElectrolytes subjectLithium-Ion Battery subjectPreprocessing subject

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