Optimizing lithium-ion battery recycling operations using handheld XRF analysis

Importance of the topic

Lithium-ion battery recycling is a strategic component of the transition to a low-carbon economy because of rising demand for battery metals (Li, Ni, Co, Cu, Mn) and the need to reduce dependence on primary mining. Efficient, safe and economically viable recycling supports circular supply chains, reduces environmental impact and helps meet regulatory requirements that increasingly hold producers responsible for end-of-life management. Rapid, on-site analytical methods are critical to manage high variability in input materials, optimize process routing, and make timely commercial and operational decisions when laboratory testing is too slow or costly relative to material value.

Objectives and overview of the application note

This application note describes how handheld X-ray fluorescence (HHXRF) instruments can be integrated into lithium-ion battery recycling workflows to:

• rapidly identify cathode chemistries and scrap types,
• screen and sort dismantled battery components and housings,
• analyze shredded fractions and black mass for valuable and hazardous elements, and
• support operational decisions that improve yield, safety and economics of downstream processes.

The document outlines typical recycling routes (mechanical separation, pyrometallurgy, hydrometallurgy), highlights where HHXRF adds value, and presents practical measurement modes (bag-level semi-quantitative and cup-based quantitative analysis).

Methodology and analytical approach

The workflow described in the note consists of several stages where elemental screening or quantification is useful: discharge and disassembly of packs, shredding and separation (magnetic, density, sieving), collection of black mass and current collectors, and downstream metallurgical processing. HHXRF is applied principally upstream and at intermediate checkpoints to inform sorting and process selection. Key analytical concepts:

• Non-destructive, near real-time elemental analysis across a broad range (Mg–U except Li), enabling fast decisions without extensive sample prep.
• Semi-quantitative screening by measuring bulk fractions inside bags for quick segregation and risk control.
• Quantitative measurements in standardized sample cups with test stands for higher precision and extended element coverage (including P, Si, Al, Fe, Cu, Ni, Co, Mn).
• Use of HHXRF results to select appropriate metallurgical routes (e.g., avoiding pyrometallurgy for LFP materials where lithium is lost to slag and recovery is costly).

Used instrumentation

The note references Thermo Scientific Niton handheld XRF analyzers as representative instruments for these tasks:

• Niton XL2 — used for rapid, semi-quantitative screening of bulk scrap and black mass in bags.
• Niton XL5 Plus — used for quantitative analysis in sample cups, providing accurate element concentrations across Mg to U for black mass and smelted alloys.

Instruments are employed with minimal sample preparation for field and process-line use, with the option to transfer material into cups and use a stand when higher accuracy is required.

Main results and discussion

The application note synthesizes practical outcomes rather than novel experimental data:

• HHXRF reliably discriminates cathode chemistries (e.g., NCM/NCA vs LFP) by measuring diagnostic metals such as Ni, Co, Mn and Fe, enabling selection of the most appropriate recycling route.
• Black mass can be screened in bags for fast, semi-quantitative metal content estimates; when higher accuracy is needed, transferring material into sample cups and using a test stand yields quantitative results across a fuller element set.
• HHXRF supports identification of hazardous contaminants (e.g., Pb, Cd), preventing their inadvertent entry into processes that could generate toxic emissions or complicate downstream recovery.
• The technique is useful for analyzing smelted alloys to determine recovery yields of Co, Ni and Cu prior to any refining steps.

The note emphasizes that while HHXRF cannot detect lithium directly, it provides critical proxy information (Ni/Co/Mn ratios and presence/absence of certain elements) that informs process decisions and economic valuation of feedstock. The technology reduces reliance on time-consuming lab assays and can materially accelerate sorting and routing decisions across the recycling chain.

Benefits and practical applications

Practical benefits highlighted include:

• Faster throughput: near real-time data enables immediate sorting and routing decisions on the plant floor.
• Cost reduction: on-site screening reduces the need for frequent lab analyses that may be more expensive than the material value.
• Improved process fit: accurate identification of cathode type avoids applying unsuitable, costly processes (e.g., pyrometallurgy on LFP feedstocks).
• Risk mitigation: detection of toxic metals early in the workflow prevents contamination of downstream streams and reduces safety and regulatory risks.
• Economic assessments: compositional data allow better estimates of material value for trading and contracting between upstream collectors and downstream recyclers.

Future trends and opportunities

Key future directions and potential uses for handheld XRF in battery recycling:

• Integration with digital workflows: automated data capture, cloud reporting and process control loops to feed sorting robots and routing decisions in real time.
• Calibration improvements: development of battery-specific calibration libraries and standard reference materials for black mass and mixed cathode chemistries to improve quantification accuracy.
• Hybrid analytical strategies: coupling HHXRF screening with targeted laboratory methods (ICP-MS, wet chemistry) for periodic validation and trace-element or light-element (Li) measurements.
• Expanded use at different supply-chain points: incoming inspection at gigafactories, QA/QC of remanufactured components, and verification for regulatory compliance and material provenance.
• Enhanced sample handling: standardized protocols for bag, cup and mounted sample analysis to reduce heterogeneity errors and improve comparability between facilities.

Conclusion

There is no single recycling route that optimally balances environmental footprint, metal recovery and economic viability for all battery chemistries. Handheld XRF provides rapid, field-deployable elemental information that helps recyclers navigate this complexity by informing sorting, routing and risk-control decisions. Although not a substitute for laboratory techniques where lithium quantification or ultra-trace analysis is required, HHXRF delivers substantial operational and commercial advantages when integrated into multi-step recycling workflows.

References

1. International Energy Agency. The Role of Critical Minerals in Clean Energy Transitions. March 2022.
2. Bird R., Baum Z. J., Yu X., Ma J. The Regulatory Environment for Lithium-Ion Battery Recycling. ACS Energy Letters, 2022, 7, 736–740.
3. Heiner Heimes et al. Recycling von Lithium-Ionen-Batterien, 2nd Edition, PEM RWTH Aachen University & VDMA, December 2023. ISBN 978-3-947920-43-3.
4. Harty J. Six key trends in the battery recycling market. Fastmarkets, June 2023.