Europe set to recycle battery materials for 2 million electric vehicles by 2030, driving industry innovation

As demand for electric vehicles soars, the environmental impact of battery production and disposal is under increasing scrutiny.

The 2023 EU Battery Regulation imposes stricter sustainability targets, requiring 50 per cent lithium recovery by 2027 and 80 per cent by 2031. By 2031, minimum recycled content levels must reach 16 per cent for cobalt, 85 per cent for lead, and 6 per cent for lithium and nickel1. These regulations drive manufacturers to enhance recycling efficiency and adapt to evolving sustainability standards.

In the US and the UK, similar legislative movements are underway, with governments pushing for a circular battery economy to mitigate the environmental impact of electric vehicle waste.

While battery recycling moves into the spotlight amid tightening regulations and rising demand for electric vehicles, Dr Umesh Tiwari, Global Segment Manager in Energy and Environment at Malvern Panalytical, explains how advanced analytical solutions could make 2025 a breakthrough year for the industry. 

Recycling capacity struggles to keep up with growing demand

Despite regulatory and technological advances, recycling capacity in the EU and UK is only a tenth of what's needed by 2030, as the electric vehicle market grows faster than material recovery capabilities. A report by Transport & Environment suggests Europe could generate enough recycled battery materials for up to two million electric vehicles by 2030, but high energy costs and limited financial support create uncertainty. 

The challenge is further compounded by outdated recycling infrastructure, making it difficult to establish a fully sustainable supply chain. To meet net-zero goals, manufacturers and recyclers must find scalable solutions to close this gap.

Aluminium's role in sustainable battery recycling

Aluminium is crucial for green battery recycling and essential to achieving the sustainability goals of electric vehicle manufacturing and energy storage. As one of the most widely used materials in these industries, it plays a key role in the green transition. Recycled aluminium saves 95 per cent of the energy needed to produce new aluminium, making its recycling vital for both economic and environmental sustainability.

Aluminium in electric vehicle battery recycling is used in battery casings and components to improve performance and reduce weight. When recycled, aluminium can be recovered and reused, minimising waste and environmental impact. Effectively integrating aluminium into battery recycling helps close the loop in the circular economy, ensuring valuable resources are reused instead of being lost to landfill.

From structural components and battery housings to thermal management and lightweighting, aluminium is integral to the electric vehicle value chain. Incorporating aluminium into battery recycling strategies can strengthen the circular economy and enhance industry efficiency while reducing reliance on newly mined resources.

Tech innovations driving efficiency

Recent technological advancements in electric vehicle battery recycling are making processes more cost-effective, efficient, and environmentally friendly. 

New hydrometallurgical and direct recycling methods are enabling the extraction of critical metals, such as lithium, cobalt, and nickel, with higher purity and lower energy consumption than traditional pyrometallurgical processes. As mining remains resource-intensive and environmentally harmful, recycling reduces reliance on virgin materials, lowers emissions, and supports a more sustainable, circular battery supply chain.

AI-driven sorting systems are improving the accuracy of separating battery components, leading to better recovery rates, the selective processing of high-cobalt batteries, and reduced contamination in recycled materials. These advancements result in lower operational costs and increased efficiency.

Analytical solutions for battery recycling

Advanced analytical solutions are key to ensuring quality control and optimising battery recycling. Understanding challenges in recycling the black mass, which is a heterogeneous mixture of cathode and anode materials, and some metals like copper and aluminium, is essential for maintaining high recycling standards. There are a few types of cathode chemistries, prominent ones being – NMC (Nickel, Manganese, Cobalt) and LMFP (Lithium Manganese Iron Phosphate). Within NMC, there are variants like NCM111, NMC622, NMC811, etc., where the number indicates the relative atomic percentage of each element. Likewise, LMFP may have a variable amount of manganese. Variable chemistry necessitates that the black mass should be properly characterised and graded before being put into the recycling process. Equally important is using cutting-edge instruments to monitor critical quality parameters during hydrometallurgical leaching and subsequent precipitation / recrystallisation to check the process efficiency and purity of the end products.

In principle, it is possible to use lab-based analytical solutions, such as Epsilon 4 for elemental composition, Mastersizer 3000+ for particle size analysis, and Aeris XRD to investigate crystalline phases. However, real-time online / inline analysers offer an added advantage of improved process efficiency through Industry 4.0 compliant automation.

Real-time elemental analysis of black mass, the material extracted from crushed electric vehicle batteries, is a major breakthrough in battery recycling. Bulk materials analysis technology, such as the CNA Pentos, revolutionises battery material recycling with high-throughput, real-time capabilities. Using a unique D-T PFTNA electric neutron generator, it accurately determines black mass composition, helping recyclers maximise the recovery of valuable metals like nickel, cobalt, manganese, and copper while minimising waste.

The efficiency of the hydrometallurgical leaching process can be evaluated using Epsilon Xflow, an inline XRF analyser that measures the concentrations of elements such as Ni, Co, and Mn in the leached solutions. Insitec, an online particle size analyser, can measure particle size in black mass or the finished end products after recycling.

As electric vehicle manufacturers and recyclers face growing sustainability demands, investing in online technologies like CNA Pentos, Epsilon Xflow, and Insitec is crucial. These solutions enable an efficient circular battery economy, reducing reliance on newly mined materials and lowering environmental impact.

Dr Umesh Tiwari, Global Segment Manager in Energy and Environment at Malvern Panalytical, said, “The path to a truly circular battery economy hinges on our ability to recover and reuse critical materials both efficiently and sustainably. As regulatory pressure intensifies and electric vehicle adoption accelerates, 2025 stands to be a pivotal year where technology, policy, and industry collaboration converge.”

“Advanced analytical solutions, like real-time, high-precision elemental analysis of black mass and hydrometallurgical solutions, are becoming essential tools. These tools bridge the gap between lab innovation and large-scale industrial application, helping recyclers optimise material recovery, lower energy use, and reduce operational costs.”

“Just as crucially, they enable the transparency and traceability needed to meet evolving compliance requirements and ESG expectations.”

Note: This article has been issued by Malvern Panalytical and has been published by AL Circle with its original information without any modifications or edits.