Life Cycle Assessment for Sustainable EV Battery Recycling: A Technical Framework for EBRR

2026-28-0092

2/12/2026

Authors
Abstract
Content
Electric vehicle (EV) battery life cycle assessment (LCA) is emerging as a strategic necessity amid booming demand and tightening environmental regulations. This report consolidates key findings and recommendations for EBRR (Electric Battery Reuse & Recycling) to implement a comprehensive LCA program covering EV lithium-ion batteries from cradle-to-grave and cradle-to-cradle perspectives. The study confirms that global Li-ion battery demand is skyrocketing – projected to increase 14-fold by 2030[1] – amplifying the urgency for sustainable battery management (see Figure 1). It outlines the full life cycle stages of EV batteries (raw material extraction, manufacturing, use, and end-of-life) and compares linear vs. circular approaches. Using the ISO 14040/44 framework[18, 19] and industry-standard LCA tools, the report evaluates environmental impacts and identifies hotspots. Key findings show that mining and manufacturing dominate the battery’s carbon footprint, but end-of-life strategies can reduce lifecycle emissions by 30–40% through hydrometallurgical recycling, renewable energy integration, and second-life battery reuse. The implementation plan details a phased approach: team setup and training, inventory data collection (3–6 months), impact assessment, interpretation, and integration into EBRR’s corporate strategy. Technical challenges – data uncertainty, regional energy variability, scaling new recycling tech, and regulatory compliance – are addressed with mitigation tactics like sensitivity analysis and scenario modeling. Finally, the roadmap recommends actionable steps: transitioning from pyrometallurgy to cleaner hydrometallurgy (cutting recycling greenhouse gas (GHG) emissions nearly in half [3]), powering battery manufacturing with renewables (potentially halving production emissions[4]), designing for disassembly and second-life reuse (extending battery life and reducing need for new materials[5, 6]), and proactive policy engagement. Implementing this LCA-driven strategy will position EBRR as a frontrunner in responsible battery stewardship, achieving verified reductions in environmental impact (~30–40% GHG reduction) while meeting or exceeding emerging global regulations such as the EU Battery Regulation 2023/1542[53]and various Extended Producer Responsibility laws. This not only mitigates environmental and social risks but also enhances long-term profitability and resilience for EBRR in the fast-evolving EV industry.
Meta TagsDetails
Pages
21
Citation
Asokan, G., Raju cEng, R., Dhananjaya, C., and Sattigeri cEng, S., "Life Cycle Assessment for Sustainable EV Battery Recycling: A Technical Framework for EBRR," SAE Technical Paper 2026-28-0092, 2026, https://doi.org/10.4271/2026-28-0092.
Additional Details
Publisher
Published
Feb 12
Product Code
2026-28-0092
Content Type
Technical Paper
Language
English