Process Safety Challenges in Lithium-ion Battery Recycling

Li, Xinqi; Hoseyni, Seyed Mojtaba; Cordiner, Joan

doi:10.22034/IJRRS.2025.8.2.3

Process Safety Challenges in Lithium-ion Battery Recycling

Document Type : Original Research Article

Authors

Xinqi Li

Seyed Mojtaba Hoseyni

Joan Cordiner

School of Chemical, Materials and Biological Engineering, The University of Sheffield, Sheffield, UK

10.22034/IJRRS.2025.8.2.3

Abstract

The rapid development of lithium-ion battery (LiB) recycling highlights its potential for addressing resource scarcity and environmental sustainability. Yet, the lack of systematic, process-specific safety frameworks means that critical hazards are often overlooked. Unlike existing studies that primarily emphasize technological advances, this study explores the process safety of LiB recycling through a struc-tured methodology. We conduct a review to map recycling processes (pretreatment, pyrometallurgy, and hydrometallurgy) and to uniquely identify and categorize the hazards arising from physical and chemical factors in these processes. In this regard, risk analysis was conducted to correlate hazards with potential accident scenarios, supported by accident case studies and industrial safety standards. To address these risks, this paper presents a comprehensive risk mitigation framework that utilizes the hierarchy of controls theory (elimination, substitution, engineering controls, administrative controls, and PPE). This methodology provides actionable recommenda-tions for policymakers and industry practitioners to address existing technological and regulatory gaps to promote safe and sustainable LiB recycling practices. These insights offer new perspectives to the evolving discussion of sustainable energy systems, emphasizing safety as a cornerstone of innovation and implementation.

Keywords

Lithium-ion battery

Recycling

Process Safety

Hazard

Risk mitigation

Subjects

Safety

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