Review of upstream processes for Li-ion batteries recycling: Safety and economic concerns

Recycling of end-of-life Lithium-Ion Batteries (LIBs) is receiving increasing attention due to the economic and environmental costs associated with battery production and the criticality of its material supply chain. However, research has focused on recycling processes, with less emphasis on the pre-treatments involving the battery packs. This review analyses state-of-the-art literature on pre-treatments for LIBs recycling, considering four main issues: residual voltage discharge, cells dismantling, organic components removal, and electrodes active material liberation and concentration into material streams destined to specific recycling treatments. The literature review revealed that current technologies applied in upstream recycling processes ensure efficient materials recovery, but there are still significant challenges in terms of safety and economic viability. Safety issues arise from inadequate voltage discharge and the release of potentially toxic emissions from organic components. Economic challenges are primarily due to the high labor costs of manual cell dismantling, which is not fully met by automated disassembly lines. In conclusion, further research should be devoted to optimizing the economic viability of the above-mentioned operations and their safety, and also to improve the recycling of anodic materials. • Pre-treatments can significantly improve the efficiency of battery recycling. • Safety improves by discharging batteries and handling electrolytes and binders. • Maximizing separation and purity of electrode materials boost recycling profitability. • Manual dismantling is an economic bottleneck due to high labour costs.