journal article·2026-07-17Open access

A Review of Graphite Anode Recycling in Lithium-Ion Batteries: Technical Challenges and Geopolitical and Economic Implications

Mina Rezaei, Anil Kumar Madikere Raghunatha Reddy, Jeremy I. G. Dawkins, Thiago M. G. Selva, Karim Zaghib

Batteries· Volume 12· Issue 7

Abstract

The rapid expansion of lithium-ion battery (LIB) use in electric vehicles and large-scale energy storage systems has intensified the need for sustainable end-of-life management. While most research and industrial efforts have focused on recovering valuable metals, graphite anodes, despite constituting a significant portion of battery mass, remain relatively overlooked. This review evaluates current progress in graphite anode recycling, emphasizing technical challenges, scalability, and economic and geopolitical considerations. Conventional recycling methods, including hydrometallurgical, pyrometallurgical, and direct recycling processes, offer viable routes for material recovery but are often constrained by high energy demands, chemical consumption, and degradation of graphite quality. Regenerated graphite exhibits competitive electrochemical performance, with initial Coulombic efficiencies above 90% and reversible capacities comparable to those of commercial materials. In addition, strategies such as surface modification and defect engineering have proven effective in restoring structural integrity and enhancing cycling stability. Despite these advances, major challenges persist in achieving cost-effective, large-scale implementation and consistent material quality suitable for reuse in battery manufacturing. Given increasing supply risks and rapidly rising global demand for graphite, advancing sustainable recycling technologies has become essential. This review emphasizes the need for integrated technological innovation and supportive policy frameworks to enable the development of a circular economy for graphite.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Extraction and Separation Processes · Advancements in Battery Materials · Fiber-reinforced polymer composites

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Department of Chemical and Materials Engineering, Concordia University, 1455 De Maisonneuve Blvd, West, Montreal, QC H3G 1M8, Canada

Funding

Concordia University

References (100+)

Show source-provided references
1. International Energy Agency (2024). World Energy Outlook 2024, International Energy Agency.
2. International Energy Agency (2024). Renewables 2024, International Energy Agency.
3. IAAM’s Pledge for Global Climate Resilience at COP 2810.5185/amlett.2024.021745 ↗
4. International Energy Agency (2023). Global EV Outlook 2023: Catching up with Climate Ambitions, International Energy Agency.
5. Direct recycling and remanufacturing of anode scraps
6. Recycling and Reusing of Graphite from Retired Lithium-ion Batteries: A Review10.1002/adma.202308494 ↗
7. Graphite Recycling from End-of-Life Lithium-Ion Batteries: Processes and Applications10.1002/admt.202200368 ↗
8. International Energy Agency (2025). Global Critical Minerals Outlook 2025, International Energy Agency.
9. Revisiting the Roles of Natural Graphite in Ongoing Lithium-Ion Batteries10.1002/adma.202106704 ↗
10. Nikgoftar, K., Madikere Raghunatha Reddy, A.K., Reddy, M.V., and Zaghib, K. (2025). Carbonaceous Materials as Anodes for Lithium-Ion and Sodium-Ion Batteries. Batteries, 11.10.3390/batteries11040123 ↗
11. Kosenko, A., Pushnitsa, K., Pavlovskii, A.A., Novikov, P., and Popovich, A.A. (2023). The Review of Existing Strategies of End-of-Life Graphite Anode Processing Using 3Rs Approach: Recovery, Recycle, Reuse. Batteries, 9.10.3390/batteries9120579 ↗
12. Separation, purification, regeneration and utilization of graphite recovered from spent lithium-ion batteries—A review10.1016/j.jece.2022.107312 ↗
13. Life cycle assessment of natural graphite production for lithium-ion battery anodes based on industrial primary data10.1016/j.jclepro.2022.130474 ↗
14. Geological Survey (2026). Mineral Commodity Summaries 2026.
15. Emily Benson, T.D. (2023). China’s New Graphite Restrictions, Center for Strategic and International Studies.
16. European Parliament (2023). CELEX_32023R1542_EN_TXT
17. Regulation (EU) 2023/1542 of the European Parliament and of the Council, European Parliament.
18. Bhuwalka, K., Ramachandran, H., Narasimhan, S., Yao, A., Frohmann, J., Peiseler, L., Chueh, C., Boies, A., Davis, S.J., and Benson, S. (2025). Securing the supply of graphite for batteries. arXiv.10.2139/ssrn.6804354 ↗
19. Assessing critical mineral occurrence in battery technologies10.1016/j.resourpol.2025.105755 ↗
20. U.S. Department of the Treasury, and Internal Revenue Service (2024). Clean Vehicle Credits under Sections 25E and 30D; Transfer of Credits; Critical Minerals and Battery Components; Foreign Entities of Concern. T.D. 9995. Fed. Regist., 89, 37706–37775. Available online: https://www.govinfo.gov/content/pkg/FR-2024-05-06/pdf/2024-09094.pdf.
21. International Energy Agency (2023). Critical Minerals Data Explorer Methodological Notes, International Energy Agency.
22. International Energy Agency (2023). Critical Minerals Market Review 2023, International Energy Agency.
23. Future of Battery Grade Graphite Recycling from Spent Batteries10.1021/acssusresmgt.5c00312 ↗
24. Challenges and strategies toward anode materials with different lithium storage mechanisms for rechargeable lithium batteries10.1016/j.est.2024.112480 ↗
25. Toward the Integration of a Silicon/Graphite Anode-Based Lithium-Ion Battery in Photovoltaic Charging Battery Systems10.1021/acsomega.2c02940 ↗
26. Overview of graphite supply chain and its challenges10.1007/s12303-025-00027-2 ↗
27. Nouveau Monde Graphite Inc. (2023). Graphite 101: Powering the Clean Energy Transition—Introduction to the Graphite Market and Associated Opportunities, Nouveau Monde Graphite Inc.. Corporate Presentation, Q2 2023.
28. The Foreseeable Future of Spent Lithium-Ion Batteries: Advanced Upcycling for Toxic Electrolyte, Cathode, and Anode from Environmental and Technological Perspectives10.1021/acs.est.3c01369 ↗
29. Efficiently regenerating spent lithium battery graphite anode materials through heat treatment processes for impurity dissipation and crystal structure repair10.1016/j.resconrec.2023.107267 ↗
30. (2025, June 03). Natural Graphite: The Material for a Green Economy. Available online: https://elements.visualcapitalist.com/natural-graphite-the-material-for-a-green-economy/.
31. Synthesis of graphene: Potential carbon precursors and approaches10.1515/ntrev-2020-0100 ↗
32. Recycling strategies for renewable graphite and other carbon nanomaterials from used batteries: A review10.1016/j.jclepro.2025.144871 ↗
33. Vegh, G., Sarah, S., Kantor, I., Amine, K., Srivastava, M., Rezayi, M., Madikere Raghunatha Reddy, A.K., and Zaghib, K. (2026). Toward Sustainable Anode Materials: LCA of Natural Graphite Processing in Québec. Batteries, 12.10.3390/batteries12020068 ↗
34. (2025, August 05). Graphite Facts—Natural Resources Canada. Available online: https://natural-resources.canada.ca/minerals-mining/mining-data-statistics-analysis/minerals-metals-facts/graphite-facts.
35. Graphite Flows in the U.S.: Insights into a Key Ingredient of Energy Transition10.1021/acs.est.2c08655 ↗
36. Prospective Life Cycle Assessment of Synthetic Graphite Manufactured via Electrochemical Graphitization10.1021/acssuschemeng.2c02937 ↗
37. Should we recycle the graphite from spent lithium-ion batteries? The untold story of graphite with the importance of recycling10.1016/j.jechem.2022.04.012 ↗
38. (2025, August 07). How Graphite in Batteries Fuels the EV Revolution. Available online: https://navprakriti.com/graphite-batteries-evs-energy-storage/.
39. Environmental Impacts of Graphite Recycling from Spent Lithium-Ion Batteries Based on Life Cycle Assessment10.1021/acssuschemeng.1c04938 ↗
40. Dasgupta, A., Buisson, E., Dhir, S., Hegarty, A., Hwang, G., Kim, Y.Y., Michaels, K.C., de Oliveira Bredariol, T., Pospiech, R., and Raboca, J. (2024). Recycling of Critical Minerals Strategies to Scale Up Recycling and Urban Mining. A World Energy Outlook Special Report, International Energy Agency.
41. Leading strategies and research advances for the restoration of graphite from expired Li+ energy storage devices10.1016/j.jece.2021.106455 ↗
42. (2025, August 07). Graphite Recycling Market to Reach $127.3 Million. Available online: https://www.globenewswire.com/news-release/2025/02/19/3028612/0/en/Graphite-Recycling-Market-to-Reach-127-3-Million-Globally-by-2033-at-9-1-CAGR-Allied-Market-Research.html.
43. US graphite sourcing for electric vehicle battery applications10.1111/jiec.70104 ↗
44. Spent graphite from lithium-ion batteries: Re-use and the impact of ball milling for re-use10.1039/D4SU00094C ↗
45. Review on the recycling of anode graphite from waste lithium-ion batteries10.1007/s10163-024-02093-4 ↗
46. (2025, July 27). Altilium Demonstrates Technology for Graphite Recycling Under UK Govt Smart Grant—Altilium. Available online: https://altilium.tech/2024/04/12/altilium-demonstrates-technology-for-graphite-recycling-under-uk-govt-smart-grant/.
47. Altilium (2026, July 01). Altilium Signs MOU to Supply Talga with Recycled Graphite. Available online: https://altilium.tech/2025/02/27/altilium-signs-mou-to-supply-talga-with-recycled-graphite/.
48. (2026, July 01). tozero Achieves Industrial-Scale Graphite Recovery, Successfully Qualifies for Lithium-Ion Batteries. Available online: https://www.tozero.solutions/press-release-graphite.
49. (2025, August 13). Nouveau Monde and Lithion Recycling Sign a Collaboration Agreement to Recycle Graphite for Reuse as Anode Material for Batteries—Showing Commitment to Full Life Cycle of Materials—Nouveau Monde Graphite. Available online: https://nmg.com/lithion-agreement/.
50. (2025, July 27). Nouveau Monde Graphite Solutions Zéro-CarboneTM. Available online: https://nmg.com/.
51. (2026, July 01). Aurubis, Talga to Develop Process for Battery-Grade Recycled Graphite—Recycling Today. Available online: https://www.aurubis.com/en/media/press-releases/press-releases-2024/aurubis-and-talga-partner-to-develop-first-of-its-kind-process-for-battery-grade-recycled-graphite.
52. (2025, August 13). Building the Most Sustainable (and Scalable) Battery Materials Process. Available online: https://www.redwoodmaterials.com/news/sustainable-battery-materials-process/.
53. (2025, August 12). Electra Battery Materials|Latest News. Available online: https://www.electrabmc.com/news-releases/news/electra-and-three-fires-group-advance-canadas-first-indigenous-led-battery-recycling-venture.
54. (2025, August 17). Eco-Responsibile Graphite Company, Recycles Graphite Elements. Available online: https://www.semcocarbon.com/blog/graphite-recycling.
55. (2025, August 17). Recycling Graphite Waste into Usable Graphite Material. Available online: https://www.semcocarbon.com/blog/recycling-graphite-waste-into-usable-graphite-material.
56. (2025, August 12). Graphite One Announces Termination of Memorandum of Understanding with Lithium-Ion Battery Anode Producer—Graphite One. Available online: https://www.graphiteoneinc.com/graphite-one-announces-termination-of-memorandum-of-understanding-with-lithium-ion-battery-anode-producer/.
57. (2025, August 17). Fortum Battery Recycling and Vianode Join Forces to Recycle Graphite from End-of-Life EV Batteries. Available online: https://www.fortum.com/services/battery-recycling/news-and-releases/fortum-battery-recycling-and-vianode-join-forces-recycle-graphite-end-life-ev-batteries.
58. (2025, August 13). Transforming Old into New: Volkswagen Group Components Commences Battery Recycling. Available online: https://www.volkswagen-group.com/en/press-releases/transforming-old-into-new-volkswagen-group-components-commences-battery-recycling-17122.
59. (2025, August 13). Volkswagen Will Use Hydrometallurgy to Recycle 95 Percent of a Cell. Available online: https://insideevs.com/news/494955/volkswagen-hydrometallurgy-recycle-95-percent-cells/.
60. (2026, July 01). PRESS RELEASE—Battery X Metals Inc. Available online: https://www.batteryxmetals.com/battery-recycling-technologies.
61. Vianode AS (2025). Sustainability Report 2024: Pioneering a Cleaner EV and Battery Industry, Vianode AS. Available online: https://vianode.fra1.digitaloceanspaces.com/documents/Vianode-Sustainability-Report-2024.pdf.
62. Li-S Batteries: Challenges, Achievements and Opportunities10.1007/s41918-023-00188-4 ↗
63. History of lithium batteries10.1007/s10008-011-1386-8 ↗
64. Toward Sustainable Lithium-Ion Batteries: Recycling and Reuse Strategies for Spent Graphite Anodes10.1002/smll.202509952 ↗
65. Recycling of graphite anode from spent lithium-ion batteries: Advances and perspectives10.1002/eom2.12321 ↗
66. Recent advancement and prospects of graphite nanocomposites as anode materials for lithium-ion batteries10.1016/j.rser.2026.117066 ↗
67. Advanced additive engineering for high-electrochemical-performance lithium-ion batteries10.1016/j.nanoen.2026.111887 ↗
68. Li-ion batteries: Basics, progress, and challenges10.1002/ese3.95 ↗
69. Recent advancements and challenges in deploying lithium sulfur batteries as economical energy storage devices10.1016/j.est.2023.108559 ↗
70. Status and prospects in sulfur–carbon composites as cathode materials for rechargeable lithium–sulfur batteries10.1016/j.carbon.2015.03.008 ↗
71. Esteve-Adell, I., Porcel-Valenzuela, M., Zubizarreta, L., Gil-Agustí, M., García-Pellicer, M., and Quijano-Lopez, A. (2022). Influence of the Specific Surface Area of Graphene Nanoplatelets on the Capacity of Lithium-Ion Batteries. Front. Chem., 10.10.3389/fchem.2022.807980 ↗
72. Intercalation chemistry of graphite: Alkali metal ions and beyond10.1039/C9CS00162J ↗
73. Progress, challenge and perspective of graphite-based anode materials for lithium batteries: A review10.1016/j.est.2023.110409 ↗
74. High-Energy Lithium-Ion Batteries: Recent Progress and a Promising Future in Applications10.1002/eem2.12450 ↗
75. Review—Development of Advanced Rechargeable Batteries: A Continuous Challenge in the Choice of Suitable Electrolyte Solutions10.1149/2.0051514jes ↗
76. Lithium-Ion Battery Technologies for Electric Vehicles: Progress and challenges10.1109/MELE.2023.3264919 ↗
77. Face to Face at the Cathode Electrolyte Interphase: From Interface Features to Interphase Formation and Dynamics10.1002/admi.202102078 ↗
78. Stampatori, D., Raimondi, P.P., and Noussan, M. (2020). Li-Ion Batteries: A Review of a Key Technology for Transport Decarbonization. Energies, 13.10.3390/en13102638 ↗
79. Enhancing the cycle life of recycled graphite materials from spent lithium-ion batteries via conductive polymer coating10.1016/j.jpowsour.2024.235864 ↗
80. Criscione, J.M., Reddy, R.L., Fulgenzi, C.F., Page, D.J., Fisher, F.F., Dzermejko, A.J., and Hedge, J.B. (2000). Graphite, Applications of Artificial. Kirk-Othmer Encyclopedia of Chemical Technology, Wiley.10.1002/0471238961.01161612.a01 ↗
81. Heteroatom-doped carbon-based materials for lithium and sodium ion batteries10.1016/j.ensm.2020.07.027 ↗
82. Recent Progress in Graphite Intercalation Compounds for Rechargeable Metal (Li, Na, K, Al)-Ion Batteries10.1002/advs.201700146 ↗
83. Mechanistic Understanding of Lithium-Ion Adsorption, Intercalation, and Plating during Charging of Graphite Electrodes10.1021/acselectrochem.4c00079 ↗
84. Preparation of mesocarbon microbeads as anode material for lithium-ion battery by co-carbonization of FCC decant oil and conductive carbon black10.1016/j.fuproc.2021.107110 ↗
85. Electrochemical and structural properties of lithium battery anode materials by using a molecular weight controlled pitch derived from petroleum residue10.1016/j.jiec.2016.07.006 ↗
86. High-Energy Batteries: Beyond Lithium-Ion and Their Long Road to Commercialisation10.1007/s40820-022-00844-2 ↗
87. Graphite formation by the dissolution—Precipitation of carbon in cobalt, nickel and iron10.1016/0008-6223(75)90267-5 ↗
88. High-temperature electrochemistry of calcium10.15826/elmattech.2022.1.007 ↗
89. A comparison of the electrochemical performance of graphitized coal prepared by high-temperature heating and flash Joule heating as an anode material for lithium and potassium ion batteries10.1016/j.cplett.2023.140362 ↗
90. Preparation of synthetic graphite from bituminous coal as anode materials for high performance lithium-ion batteries10.1016/j.fuproc.2017.12.018 ↗
91. Coal-derived synthetic graphite with high specific capacity and excellent cyclic stability as anode material for lithium-ion batteries10.1016/j.fuel.2021.120250 ↗
92. Catalytic Graphitization of Anthracite as an Anode for Lithium-Ion Batteries10.1021/acs.energyfuels.0c00995 ↗
93. Low-Cost Transformation of Biomass-Derived Carbon to High-Performing Nano-graphite via Low-Temperature Electrochemical Graphitization10.1021/acsami.0c19395 ↗
94. The success story of graphite as a lithium-ion anode material—Fundamentals, remaining challenges, and recent developments including silicon (oxide) composites10.1039/D0SE00175A ↗
95. Review on Graphite Anodes for Fast-Charging Lithium-Ion Batteries: Mechanism, Modification and Characterizations10.1002/adfm.202506190 ↗
96. Graphite, semi-graphite, natural coke, and natural char classification—ICCP system10.1016/j.coal.2003.09.003 ↗
97. Influence of abrasives and graphite on processing and properties of sintered metallic friction materials10.1016/j.heliyon.2019.e02311 ↗
98. Park, J., Xu, Z.-L., and Kang, K. (2020). Solvated Ion Intercalation in Graphite: Sodium and Beyond. Front. Chem., 8.10.3389/fchem.2020.00432 ↗
99. Phase diagram of LixC610.1103/PhysRevB.44.9170 ↗
100. The mechanism of lithium intercalation in graphite film electrodes in aprotic media. Part 1. High resolution slow scan rate cyclic voltammetric studies and modeling10.1016/S0022-0728(96)04832-2 ↗