The Global Market for Li-ion Battery Recycling 2024-2040

1              INTRODUCTION 

• 1.1          Lithium-ion batteries      11
  • 1.1.1      What is a Li-ion battery?               13
  • 1.1.2      Li-ion cathode   16
  • 1.1.3      Li-ion anode       19
  • 1.1.4      Battery failure   20
  • 1.1.5      End-of-life          21
  • 1.1.6      Sustainability     23
• 1.2          The Electric Vehicle (EV) market 23
  • 1.2.1      Emerging market for replacement battery packs 24
  • 1.2.2      Closed-loop value chain for EV batteries 25
• 1.3          Lithium-Ion Battery recycling value chain               25
• 1.4          Circular life cycle              26
• 1.5          Global regulations and policies   28
  • 1.5.1      China     29
  • 1.5.2      EU          31
  • 1.5.3      US          32
  • 1.5.4      India      33
  • 1.5.5      South Korea       33
  • 1.5.6      Japan    33
  • 1.5.7      Australia              34
  • 1.5.8      Transportation  34
• 1.6          Sustainability and environmental benefits            35

2              RECYCLING METHODS AND TECHNOLOGIES         37

• 2.1          Black mass powder         38
• 2.2          Recycling different cathode chemistries 39
• 2.3          Preparation        40
• 2.4          Pre-Treatment  40
  • 2.4.1      Discharging         40
  • 2.4.2      Mechanical Pre-Treatment          40
  • 2.4.3      Thermal Pre-Treatment 43
• 2.5          Comparison of recycling techniques        44
• 2.6          Hydrometallurgy              45
  • 2.6.1      Method overview            45
    • 2.6.1.1   Solvent extraction           47
  • 2.6.2      SWOT analysis   47
• 2.7          Pyrometallurgy 49
  • 2.7.1      Method overview            49
  • 2.7.2      SWOT analysis   49
• 2.8          Direct recycling 51
  • 2.8.1      Method overview            51
    • 2.8.1.1   Electrolyte separation    52
    • 2.8.1.2   Separating cathode and anode materials               53
    • 2.8.1.3   Binder removal 53
    • 2.8.1.4   Relithiation         53
    • 2.8.1.5   Cathode recovery and rejuvenation         54
    • 2.8.1.6   Hydrometallurgical-direct hybrid recycling            55
  • 2.8.2      SWOT analysis   56
• 2.9          Other methods 57
  • 2.9.1      Mechanochemical Pretreatment              57
  • 2.9.2      Electrochemical Method               57
  • 2.9.3      Ionic Liquids       58
• 2.10        Recycling of Specific Components             58
  • 2.10.1    Anode (Graphite)            58
  • 2.10.2    Cathode               58
  • 2.10.3    Electrolyte          59
• 2.11        Recycling of Beyond Li-ion Batteries         59
  • 2.11.1    Conventional vs Emerging Processes       60
  • 2.11.2    Li-Metal batteries            61
  • 2.11.3    Lithium sulfur batteries (Li–S)     62
  • 2.11.4    All-solid-state batteries (ASSBs) 63

3              MARKET ANALYSIS          64

• 3.1          Market drivers  64
• 3.2          Market challenges           65
• 3.3          The current market         65
• 3.4          Recent market news, funding and developments               67
• 3.5          Economic case for Li-ion battery recycling             70
  • 3.5.1      Metal prices       71
  • 3.5.2      Second-life energy storage          72
  • 3.5.3      LFP batteries      72
  • 3.5.4      Other components and materials              73
  • 3.5.5      Reducing costs  73
• 3.6          Competitive landscape  74
• 3.7          Global capacities, current and planned   76
• 3.8          Future outlook  77
• 3.9          Global market 2018-2040              78
  • 3.9.1      Chemistry           79
  • 3.9.2      Ktonnes               81
  • 3.9.3      Revenues            82
  • 3.9.4      Regional               84
    • 3.9.4.1   Europe 87
      • 3.9.4.1.1               Regional overview           87
    • 3.9.4.2   China     88
      • 3.9.4.2.1               Regional overview           88
    • 3.9.4.3   Rest of Asia-Pacific          90
      • 3.9.4.3.1               Regional overview           90
    • 3.9.4.4   North America   92
      • 3.9.4.4.1               Regional overview           92

4              COMPANY PROFILES       94

5              TERMS AND DEFINITIONS             162

6              RESEARCH METHODOLOGY         164

7              REFERENCES       165

List of Tables

• Table 1.  Lithium-ion (Li-ion) battery supply chain.             13
• Table 2. Commercial Li-ion battery cell composition.        13
• Table 3. Key technology trends shaping lithium-ion battery cathode development.            17
• Table 4. Cathode Materials Used in Commercial LIBs and Recycling Methods.       18
• Table 5. Fate of end-of-life Li-ion batteries.          22
• Table 6. Closed-loop value chain for electric vehicle (EV) batteries.            25
• Table 7. Li-ion battery recycling value chain.         26
• Table 8. Potential circular life cycle for lithium-ion batteries.        27
• Table 9. Regulations pertaining to the recycling and treatment of EOL batteries in the EU, USA, and China               28
• Table 10. China regulations and policies related to batteries.        30
• Table 11. Sustainability and environmental benefits of Li-ion recycling.    35
• Table 12. Typical lithium-ion battery recycling process flow.          38
• Table 13. Main feedstock streams that can be recycled for lithium-ion batteries. 38
• Table 14. Comparison of LIB recycling methods. 44
• Table 15. Comparison of conventional and emerging processes for recycling beyond lithium-ion batteries.              60
• Table 16. Market drivers for lithium-ion battery recycling.              64
• Table 17. Market challenges in lithium-ion battery recycling.        65
• Table 18. Recent market news, funding and developments in Li-ion battery recycling.        67
• Table 19. Economic assessment of battery recycling options.        70
• Table 20. Retired lithium-batteries.          74
• Table 21. Global capacities, current and planned (tonnes/year). 76
• Table 22. Global lithium-ion battery recycling market in tonnes segmented by cathode chemistry, 2018-2040.        79
• Table 23. Global Li-ion battery recycling market, 2018-2040 (ktonnes)     81
• Table 24. Global Li-ion battery recycling market, 2018-2040 (billions USD).             82
• Table 25. Li-ion battery recycling market, by region, 2018-2040 (ktonnes).             85
• Table 26. Li-ion battery recycling market, in Europe, 2018-2040 (ktonnes).            87
• Table 27. Li-ion battery recycling market, in China, 2018-2040 (ktonnes). 89
• Table 28. Li-ion battery recycling market, in Rest of Asia-Pacific, 2018-2040 (ktonnes).     91
• Table 29. Li-ion battery recycling market, in North America, 2018-2040 (ktonnes).             92

List of Figures

• Figure 1. Li-ion battery cell pack.               12
• Figure 2. Lithium Cell Design.      15
• Figure 3. Functioning of a lithium-ion battery.     16
• Figure 4. LIB cathode recycling routes.    19
• Figure 5. Process for recycling lithium-ion batteries from EVs.      24
• Figure 6. Circular life cycle of lithium ion-batteries.           28
• Figure 7. Typical direct, pyrometallurgical, and hydrometallurgical recycling methods for recovery of Li-ion battery active materials.               37
• Figure 8. Mechanical separation flow diagram.    41
• Figure 9. Recupyl mechanical separation flow diagram.   42
• Figure 10. Flow chart of recycling processes of lithium-ion batteries (LIBs).             45
• Figure 11. Hydrometallurgical recycling flow sheet.          46
• Figure 12. SWOT analysis for Hydrometallurgy Li-ion Battery Recycling.    48
• Figure 13. Umicore recycling flow diagram.           49
• Figure 14. SWOT analysis for Pyrometallurgy Li-ion Battery Recycling.       50
• Figure 15. Schematic of direct recyling process.  52
• Figure 16. SWOT analysis for Direct Li-ion Battery Recycling.         56
• Figure 17. Schematic diagram of a Li-metal battery.          62
• Figure 18. Schematic diagram of Lithium–sulfur battery. 62
• Figure 19. Schematic illustration of all-solid-state lithium battery.              63
• Figure 20.  Global scrapped EV (BEV+PHEV) forecast to 2040.        78
• Figure 21. Global Li-ion battery recycling market, 2018-2040 (chemistry).               80
• Figure 22. Global Li-ion battery recycling market, 2018-2040 (ktonnes)    82
• Figure 23. Global Li-ion battery recycling market, 2018-2040 (Billion USD).             83
• Figure 24. Global Li-ion battery recycling market, by region, 2018-2040 (ktonnes).             86
• Figure 25. Li-ion battery recycling market, in Europe, 2018-2040 (ktonnes).           88
• Figure 26. Li-ion battery recycling market, in China, 2018-2040 (ktonnes).              90
• Figure 27. Li-ion battery recycling market, in Rest of Asia-Pacific, 2018-2040 (ktonnes).    92
• Figure 28. Li-ion battery recycling market, in North America, 2018-2040 (ktonnes).            93

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The Global Market for Li-ion Battery Recycling 2024-2040

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