Comprehensive End-of-Life-Battery Composition Analysis from Module to Electrode Level to Assist More Efficient Recycling

With rising efforts to enable a circularity of valuable resources of lithium-ion batteries, a growing number of recycling companies in Europe are expanding their capacities and developing new recycling technologies. The European Union (EU) has set a benchmark for battery recycling by publishing recycling targets. These targets require precise mass determination of the individual battery components, making disassembly of the battery mandatory for characterization. The paper puts forth a semi-automated disassembly procedure for determining the composition of the components at the module and cell levels across a range of designs. Our analysis incorporates the introduction of TGA as a novel, direct method for determining the cathode active material with an accuracy above 99%. This approach is intended to define the recycling input for all extant recycling routes by providing quantitative experimental results with statistical significance. The results indicate a black mass proportion of 61.6% at the module level and 53–74% at the cell level. Additionally, there are significant differences in value creation, ranging from 0.80 to 1.81 USD kg⁻¹ black mass, depending on the cell chemistry. The procedure can be used for EoL and scrap material, and enables greater transparency and comparability in battery recycling, opening up new perspectives for the resource-efficient and targeted use of various recycling technologies.