Publication date: 21st July 2025
Secondary raw materials, derived from battery recycling, is considered a valuable source of critical materials by Europe. State-of-the-art recycling processes based on pyrometallurgy and hydrometallurgy recover critical elements such as lithium, nickel or cobalt either as metal alloys or metal salts, which can then be transformed by new synthesis into cathode active materials (CAM). Direct recycling provides an interesting alternative, which retains the active material structure, and thus avoids the step of CAM synthesis.
In the short-term, direct recycling is particularly attractive for production scrap, where the degradation of the CAM is minimal. In comparison, direct recycling of end-of-life materials is more complicated, as structural defects must be repaired and lost lithium must be replaced. The situation is then more complicated when the recycled materials are based on cathode chemistry that are no longer considered state-of-the-art. This contribution will discuss the reuse of active materials recovered from direct recycling processes, including a discussion of upcycling old CAM stoichiometries.
This project has received funding from the European Union’s Horizon Europe research and innovation programme under grant agreement N° 101069865. This output reflects only the authors’ view and the European Union cannot be held responsible for any use that may be made of the information contained therein.
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