Direct recycling of Li‐ion batteries from cell to pack level: Challenges and prospects on technology, scalability, sustainability, and economics

Abstract Direct recycling is a novel approach to overcoming the drawbacks of conventional lithium‐ion battery (LIB) recycling processes and has gained considerable attention from the academic and industrial sectors in recent years. The primary objective of directly recycling LIBs is to efficiently recover and restore the active electrode materials and other components in the solid phase while retaining electrochemical performance. This technology's advantages over traditional pyrometallurgy and hydrometallurgy are cost‐effectiveness, energy efficiency, and sustainability, and it preserves the material structure and morphology and can shorten the overall recycling path. This review extensively discusses the advancements in the direct recycling of LIBs, including battery sorting, pretreatment processes, separation of cathode and anode materials, and regeneration and quality enhancement of electrode materials. It encompasses various approaches to successfully regenerate high‐value electrode materials and streamlining the recovery process without compromising their electrochemical properties. Furthermore, we highlight key challenges in direct recycling when scaled from lab to industries in four perspectives: (1) battery design, (2) disassembling, (3) electrode delamination, and (4) commercialization and sustainability. Based on these challenges and changing market trends, a few strategies are discussed to aid direct recycling efforts, such as binders, electrolyte selection, and alternative battery designs; and recent transitions and technological advancements in the battery industry are presented.