India's electric vehicle (EV) revolution is gaining momentum, driven by government initiatives and a growing focus on sustainability. However, while our consumer behaviours are evolving, the foundational aspect of our production systems—the "take-make-dispose" model—remains largely unchanged. This linear approach is at odds with the sustainability goals we strive for. 

This is where the circular economy emerges as a game-changer, shifting us from a linear mindset to a closed-loop system where resources are continuously recovered and reused. An economy with a circular model prioritises extending product life cycles, minimising waste generation and maximising resource recovery. All of the things that Shoonya aims to do through lithium-ion battery recycling. Let’s find out how. 

Lithium-ion Battery Recycling Process

Recycling lithium-ion batteries is a complex, multi-stage process, with each stage tailored to optimise the recovery of valuable materials. These stages can differ on the basis of different recycling technologies used, the battery chemistries and also depending on the expected output quality. However, the four main stages are: preparation, pre-treatment, pyrometallurgy, and hydrometallurgy. Here's a detailed look at each stage and the outputs achieved:

1. Preparation:
• Discharging, Dismantling, and Sorting: Batteries are first fully discharged for safety, then dismantled into smaller cells or modules, with external materials like steel, aluminium, plastics, and electronics separated. Finally, the components are sorted by type and weight, which helps in planning the recycling process. This stage can be manual or automated and is crucial for effective recycling despite being optional.
  
  
2. Pre-Treatment:
• Pyrolysis: Batteries are subjected to high temperatures to decompose organic components without oxidising metals. This process helps in separating organic materials and also generates energy for other industrial processes.
• Mechanical Processing: Batteries undergo crushing and shredding, yielding iron, copper, and aluminium flakes, as well as electrode powder containing cobalt and nickel. Magnetic separators extract iron from the mix, while density separators distinguish copper and aluminium flakes.
  
  
3. Pyrometallurgy:
• This stage involves high-temperature processing to remove undesirable materials such as electrolytes, phosphorus, graphite, and plastics. The remaining materials, often called slag, are used in construction. Pyrometallurgy produces fewer impurities in the output.

1. Hydrometallurgy:
• Cobalt and Nickel Salts Production: This stage focuses on extracting metals from their salts. The process recovers high-purity cobalt and nickel, essential for new battery production and other industrial applications.

Energy Transition: Materials obtained from Recycling

The recycling process yields several valuable outputs such as Iron, Aluminium, Copper, Plastics and Black Mass rich in cobalt, nickel, copper, and lithium, all of which enter the supply chain again in the form of raw materials for industry manufacturing or are traded amongst local smelters. 

The Economic Impact

• Reduced Import Dependence: India spent a whopping Rs 163 billion (USD 1.97 billion) between April - December 2022 to import lithium and lithium-ion. Lithium and cobalt, critical for most rechargeable batteries, are not produced in India and are imported from countries like Chile and Democratic Republic of Congo respectively. So, by reducing dependence on raw materials imports, India can enhance its supply chain resilience.
  
  

1. Better Prices for Recycled Materials: Investing in advanced recycling technologies and establishing a coherent regulatory framework can help India achieve higher recycling rates and improve the quality of recovered materials. By incentivizing stakeholders and promoting public awareness, India can build a sustainable and efficient recycling infrastructure. 

The Environmental Impact

1. Avoiding Contamination- Improper disposal of lithium-ion batteries in landfills can lead to environmental catastrophe. Landfilled batteries leak toxic chemicals, contaminating soil and water sources which get absorbed and accumulated in edible plants and enter the food chain, causing various genetic, reproductive, and gastrointestinal problems. Recycling keeps these hazardous materials out of landfills and prevents them from harming our environment. 

1. Human Health Risks: With formal recycling infrastructure, communities no longer have to resort to unsafe methods of disposing used batteries. Slums in Delhi and Mumbai who bear the brunt of informal E-waste management have workers, including children, who handle toxic battery waste in the absence of any protective equipment. This increases the chances of developing serious health risks to those involved in the process. 

Lithium-ion battery recycling presents a unique opportunity to power India's sustainable future and build a circular economy where we create a closed loop between the start and end processes of manufacturing. As the demand for electric vehicles and consumer electronics continues to rise, developing a robust recycling ecosystem will be essential in supporting India's green agenda and achieving long-term sustainability goals.