Impact of impurities from recycled materials on battery safety and life cycle

As the global demand for lithium-ion batteries (LIBs) continues to rise, battery recycling has become a critical strategy for mitigating resource depletion, minimizing environmental impact, and advancing a circular economy. However, recycled electrode materials, particularly cathode and anode powders, often contain residual impurities such as transition metals (e.g., Cu, Fe, Al), polymeric binders (e.g., PVDF), and the electrolyte decomposition products. These contaminants can significantly impair the electrochemical performance, thermal stability, and overall safety of newly manufactured cells.

This study aims to systematically investigate the nature, origin, and impact of impurities in recycled cathode and anode materials. A suite of analytical techniques, including inductively coupled plasma mass spectrometry (ICP-MS), infrared spectroscopy (IR), scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS), and thermogravimetric analysis (TGA), will be employed to quantify impurity levels and assess material integrity across various recycling streams.The findings are expected to inform the establishment of impurity threshold limits for battery-grade recycled materials and guide the development of enhanced purification protocols. Ultimately, this research will support the production of safer and more reliable second-life batteries, offering valuable insights to recyclers, manufacturers, and regulatory bodies committed to sustainable energy storage technologies.