Navigating the Challenges of EV Battery Recycling: A Problem-Solution Perspective

As electric vehicles (EVs) become more common due to shifts in consumer demand worldwide, greater attention must be given to this industry, particularly the recycling aspect, since EVs are projected to account for more than 60% of new car purchases by 2040 (Safarzadeh & Di Maria, 2025). Although numerous researchers have contributed to creating a sustainable and efficient EV market, a significant challenge still looms. The lack of battery standardization across the industry has created numerous issues for market participants, slowing progress in developing safe and efficient recycling methods. Currently, each manufacturer has its own battery design, which causes friction in the recycling process due to inefficiencies and the dangers associated with disassembling diverse battery types. This essay will discuss the history of EV battery recycling, the current state of the problem, existing solutions, and a proposed solution.

Problem’s History

Electric vehicles have existed for roughly 195 years, but this essay focuses primarily on the industry from the early 21st century onward, when EV battery recycling began to gain momentum. This momentum was driven by the growing popularity of electric vehicles among consumers. With the mass release of the Nissan Leaf and Chevy Volt, along with advancements in battery technology, consumers worldwide began to view these electric vehicles as a viable solution for a more sustainable transportation system. As the number of EVs on the road increased, manufacturers began to discuss the challenges of battery recycling, highlighting an important and complex issue for the industry.

Current State of the Problem

Prominent challenges in EV battery recycling include dangerous disassembly practices, inadequate screening technology, and weak industry infrastructure. Regarding disassembly, the safety risk is tied to the variation in battery designs. As Elsa Olivetti states in an interview with Andrew Moseman, “The significant challenge in battery recycling is the variability in chemistry and form factor, and that we have to be cautious to discharge them when they are recovered. That’s especially important because old or broken lithium-ion batteries can catch fire, which adds to the danger of stockpiling them for disposal” (Moseman, 2023). The variety of battery styles, combined with the dangers associated with disassembly, creates bottlenecks that slow the entire industry.

Data gathering is another challenge. Hanyu and her team, in their paper Challenges and Opportunities for Second-Life Batteries: Key Technologies and Economy, emphasized that further research is needed to determine the most effective methods for gathering data to screen batteries, thereby improving recycling efficiency. Lastly, the current infrastructure of the EV battery industry is insufficient. Di Maria and Safarzadeh note in their work, Progress, Challenges and Opportunities in Recycling Electric Vehicle Batteries: A Systematic Review Article, that the industry’s infrastructure is underdeveloped, which contributes to stagnation. Despite these challenges, researchers continue to work toward solutions, as battery recycling will become increasingly essential in the coming decade as more EV batteries reach the end of their life.

Proposed Solution

The greatest challenge in EV battery recycling is the lack of standardization in battery packs. Elsa Olivetti’s statement, “The significant challenge in battery recycling is the variability in chemistry and form factor,” underscores the need for standardization. Standardizing battery packs could simplify recycling processes, reduce safety risks, and improve efficiency. Leading EV manufacturers such as Tesla, Rivian, and General Motors should collaborate to agree on a standardized battery pack design. This change would not only streamline recycling but also make the market more attractive to investors by improving efficiency and profitability.

Although the benefits of standardization are clear, implementing this change has proven difficult. Di Maria and Safarzadeh (2025) highlight that a lack of cohesion within the industry—stemming from poor communication between policymakers and manufacturers—has prevented progress. Steve Hudnut, a manufacturing industry professional with over 25 years of experience, reinforces this point: “Your business guys, your managers, they’re thinking about this quarter’s result. They’re not thinking 20 years from now” and “You have to force them… the government has to get involved and say you have to plan for the life cycle of these… you can’t just put the batteries out in the world with no plans for it” (S. Hudnut, personal communication, 2025).

Based on this, my proposed solution is to raise awareness of the benefits of battery standardization. First, I would gather a volunteer group passionate about this issue. The group would conduct thorough research on the advantages of standardization and compile a detailed report. This initial stage would likely take about a year due to the voluntary nature of the group. Next, we would meet with the CEO of a local recycling plant to understand how opinions travel up the chain of influence and to gather information for future meetings. These discussions would also provide opportunities to connect with other recycling plant leaders interested in our cause.

Over the following 3–5 years, the group would aim to expand its network to include recycling plant CEOs at the national level. With their support, discussions with EV battery manufacturers could begin. The full process, from research to national-level advocacy, would likely take over a decade. However, this long-term effort is necessary because progress in the EV battery recycling industry has been slow, and standardization could greatly improve efficiency, safety, and profitability.

Conclusion

EV battery recycling is a relatively new industry that requires careful attention. Creating a reliable and efficient recycling system through battery standardization is essential for its growth. Understanding and addressing the current challenges—such as dangerous disassembly, weak infrastructure, and a lack of cohesion among industry participants—is a crucial first step. With a strong foundation, future researchers and industry leaders can implement permanent solutions that improve efficiency and safety. Building this infrastructure will not only benefit the present generation but also ensure that future EV users and manufacturers inherit a sustainable, well-organized system. Progress will only occur if manufacturers take the necessary risks, but researchers and advocates can help persuade them to act.

References

Alvez, W., Santos, A. L., & Ferreira, P. (2025). Challenges faced by lithium-ion batteries in effective waste management. Sustainability, 17(7), 2893. https://doi.org/10.3390/su17072893

Bai, H., Gu, X., Cui, X., Zhu, J., Zhuang, W., Li, Z., Hu, X., & Song, Z. (2024). Challenges and opportunities for second-life batteries: A review of key technologies and economy. Renewable and Sustainable Energy Reviews, 214, 114191. https://doi.org/10.1016/j.rser.2023.114191

Di Maria, F., & Safarzadeh, H. (2025). Progress, challenges and opportunities in recycling electric vehicle batteries: A systematic review article. Batteries, 11(6), 230. https://doi.org/10.3390/batteries11060230

Moseman, A. (2023). How well can electric vehicle batteries be recycled? Climate Portal. https://climate.mit.edu/ask-mit/how-well-can-electric-vehicle-batteries-be-recycled

Shah, V. (2024). EU battery recycling industry faces multiple scale-up challenges. S&P Global.https://www.spglobal.com/commodity-insights/en/news-research/latest-news/energy-transition/112824-eu-battery-recycling-industry-faces-multiple-scale-up-challenges

This article is authored by Francisco Gonzalez Rodriguez.

Also Read: Trends in Lithium-ion Battery Reuse and Recycling