Advancements in lithium-ion battery recycling technologies: Exploring module-scale crushing and air separation techniques

The rapid expansion of electric vehicles (EVs) and renewable energy storage systems has driven a surge in the demand for lithium-ion batteries (LIBs), creating an urgent need for efficient and sustainable recycling technologies. As LIBs reach their end-of-life, the recovery of key materials, such as electrodes, separators, cell pouches, and plastics, is critical for both environmental protection and resource conservation. This study presents a novel zig-zag air separation technique, integrated with module-scale crushing, to optimize the recycling of crushed LIB modules. By fine-tuning particle size and airflow rates, the method effectively separates components larger than 2 mm, achieving recovery rates exceeding 95% for electrodes and cell pouches, and over 97% for plastics larger than 3.35 mm. The variability in plastic recovery highlights the necessity of precise particle size control. This approach not only enhances recycling efficiency but also reduces contamination risks and minimizes the burden on downstream processing steps. The findings demonstrate the potential of this technique as a scalable and sustainable solution to address the challenges of LIB recycling, offering a pathway to greater material circularity and reduced environmental impact.