Sponsored By

How XRF and Raman Technologies Enhance Lithium-Ion Battery RecyclingHow XRF and Raman Technologies Enhance Lithium-Ion Battery Recycling

Thermo Fisher Scientific highlights how XRF and Raman technologies improve lithium-ion battery recycling efficiency, aiding material recovery and sustainability efforts.

Kyle D’Silva, Director of Clean Energy for Analytical Instruments

January 13, 2025

5 Min Read
XRF and Raman technologies
Manufacturers must improve their ability to recover and repurpose battery materials. Alexander Gabriel/iStock / Getty Images Plus

As our reliance on technology grows, so does the volume of lithium-ion batteries used around the globe to power many of these technologies – from our cars to remote entertainment systems and battery-powered home equipment. According to McKinsey, the demand for these batteries continues to surge, emphasizing the critical need for effective recycling practices when these batteries reach end-of-life.  Despite significant efforts, most recycling processes in the battery industry are still inefficient, with an average scrap rate of about 50% in Europe and North America. However, many companies are striving to do better, including Tesla, who previously shared that their scrap rate for batteries had decreased by almost 60% due to improved manufacturing processes.

Lithium-ion batteries power a wide array of devices, from smartphones to electric vehicles (EVs), and are significant drivers of innovation, which shapes our evolving digital landscape. Yet, mining new materials is insufficient to meet the growing demand for lithium-ion batteries, which the World Economic Forum has highlighted as a concern in recent years. Lithium-ion batteries rely heavily on nickel, manganeses, cobalt, and lithium, which can present significant challenges in extraction and supply.

Related:Closed-Loop Systems: BMW, SK tes, & the Future of Sustainable Battery Recycling

Cobalt mining is concentrated in politically unstable regions and is often associated with human rights abuses, while lithium extraction can lead to environmental degradation and water scarcity. The uneven geographical distribution of these critical minerals exacerbates supply chain vulnerabilities and increases the risk of price fluctuations. Manufacturers must improve their ability to recover and repurpose materials to meet the market's needs. Effective recycling practices alleviate the pressure on mining and contribute to environmental sustainability. Advanced technologies such as X-ray fluorescence (XRF), Raman spectroscopy, and more are crucial in advancing battery recycling processes by helping to identify and measure materials to improve recycling yield and reduce waste.

Breaking down the battery and managing black mass

While increasing recycling efforts has many benefits, it also has many challenges. One of the main difficulties of battery recycling is identifying pure substances that can be extracted and reused for future battery manufacturing. Disassembling, crushing, shredding, and processing used batteries create a waste stream referred to as black mass. This mixture contains valuable metals such as nickel (Ni), manganese (Mn), cobalt (Co), and lithium (Li), making it a critical focus in recycling efforts.

Related:AI Battery Recycling Innovation: No Barcode Needed

Regulations, particularly in the EU, emphasize sustainability and extended producer responsibility, making the processing of black mass increasingly important and profitable. Recently, The Council of the European Union implemented a regulation that sets targets for producers to collect waste portable batteries (63% by the end of 2027 and 73% by the end of 2030). Analytical techniques are essential for certifying maximum impurity levels and differentiating waste streams for optimal processing.

To support the need for high material assurance and processing of materials, XRF analyzers offer real-time elemental analysis to help rapidly screen and separate incoming material by cathode chemistry type. These analyzers can determine the content of black mass and its impurities. XRF technology is increasingly used in recycling processes, providing elemental analysis crucial for developing and monitoring the recovery of metals at some of the fastest speeds. In the hydrometallurgical processing of black mass, in particular, XRF aids the recovery of valuable metal salts by optimizing reaction endpoints as acidic or basic process streams are precipitated to solid salts. Throughout the recycling process, XRF will come back into play multiple times.

Related:Case Study: Repurposed Batteries Deliver Cost-Saving Sustainability in Phoenix

The promise of precise control

Precise control in recycling ensures the extraction of valuable materials with minimal loss, enhancing both economic viability and environmental sustainability. Technologies like XRF and Raman spectroscopy provide the necessary precision for effective recycling processes. In recent years, a U.S.-based battery recycling company harnessed the capabilities of Raman spectroscopy for its hydrometallurgical platform.

XRF and Raman technologies

Raman spectroscopy provides detailed chemical information by analyzing the scattered light from a sample illuminated by a laser. In recycling, this technique excels at identifying and quantifying materials, monitoring process dynamics, and assessing the quality of recovered materials. This technology significantly enhanced the efficiency and yield of recycling essential elements like Co, Li, and Mn from cathode active materials.

Additionally, beyond the battery breakdown, online Raman spectroscopy systems enabled real-time monitoring and adjustment of recycling processes, improving efficiency. While Raman spectroscopy is blind to elemental metals, it can be sensitive to metal oxides, sulphates, phosphates, and carbonates. The continuous monitoring of reactions led to higher recovery rates and minimized waste. Moreover, Raman spectroscopy provides immediate insights into reaction progress, allowing better control over reactions and reducing waste and reagent consumption.

Future directions and implications

Continued research and development are essential to overcoming battery recycling challenges and unlocking the full potential of innovative analytical solutions. Technologies like XRF, Raman spectroscopy, and more are at the forefront of these efforts, and embracing them is crucial for realizing a sustainable future in battery recycling. These technologies drive innovation and sustainability in the field, ensuring that the recycling processes are efficient, cost-effective, and environmentally friendly.

The integration of XRF, Raman spectroscopy, and other advanced analytical techniques in battery recycling not only enhances the recovery and reuse of valuable materials but also sets the stage for a more sustainable and economically viable future in battery lifecycle management. By continually advancing these technologies and processes, the industry can meet the growing demand for lithium-ion batteries while minimizing environmental impact.

About the Author

Kyle D’Silva

Director of Clean Energy for Analytical Instruments, Thermo Fisher Scientific

D’Silva is an Analytical Chemist with expertise in spectroscopy, chromatography, and mass. He is responsible for the strategic and market development of analytical instrument portfolios that serve the battery, solar, carbon storage, biofuels, and hydrogen end markets.

Sign up for Battery Technology newsletters

You May Also Like