With EU and UK recycling capacity at just 10% of 2030 targets, Dr. Umesh Tiwari of Malvern Panalytical discusses how 2025 could be a turning point.
As demand for electric vehicles soars, the environmental impact of battery production and disposal is under scrutiny.
The 2023 EU Battery Regulation requires 50% lithium recovery by 2027 and 80% by 2031.
By 2031, minimum recycled content levels must reach 16% for cobalt, 85% for lead, and 6% for lithium and nickel1.
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 EV waste.
Recycling capacity struggles to keep up with demand
Despite regulatory and technological advances, recycling capacity in the EU and UK is only a tenth of what’s needed by 20302, as the rapid growth of the electric vehicle market continues to outpace material recovery capabilities.
According to a report by Transport & Environment, Europe could generate enough recycled battery materials to support up to two million electric vehicles by 20303.
However, high energy costs and limited financial backing cast uncertainty on reaching this goal.
Limited infrastructure and outdated recycling facilities further compound the issue, making it difficult to establish a fully sustainable supply chain. As the push for net-zero emissions continues, manufacturers and recyclers must find scalable solutions to close this gap.
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 like lithium, cobalt, and nickel with higher purity and lower energy use 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 efficiency4.
Analytical solutions
Advanced analytical solutions are key to ensuring quality control and optimising battery recycling. Understanding challenges in manufacturing cathode and anode materials, as well as crystallographic defects, is essential for maintaining high production standards. Equally important is using cutting-edge instruments to monitor critical quality parameters.
Real-time elemental analysis of black mass, the material extracted from crushed electric vehicle batteries, is a major breakthrough in recycling.
Technology such as the CNA Pentos system revolutionises battery material analysis 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, and copper while minimising waste.
As electric vehicle manufacturers and recyclers face growing sustainability demands, investing in technologies like CNA Pentos is crucial. These advancements drive a circular battery economy, reducing reliance on newly mined materials and lowering environmental impact.
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, 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.
Dr. Umesh Tiwari, Global Segment Manager for Energy and Environment at Malvern Panalytical, holds a Ph.D. in physics and has 17 years of experience in academia and industry. Specialising in structural, elemental, and morphological characterisation, he focuses on lab and online solutions for research and process optimisation.
References
https://www.consilium.europa.eu/en/press/press-releases/2023/07/10/council-adopts-new-regulation-on-batteries-and-waste-batteries/
https://www.reuters.com/world/europe/europe-set-miss-potential-battery-material-recycling-2024-12-11/
https://www.transportenvironment.org/articles/from-waste-to-value-the-potential-for-battery-recycling-in-europe
https://www.mdpi.com/3083530
