Future Days Battery Edition recap: Advanced analytics unlock the true value of battery waste

On May 21, Malvern Panalytical hosted the Future Days: Focus on Battery virtual event, featuring a range of speakers from across industry and academia. Read on for a recap of Rajendra Mishra and Michel Zoontjes‘ session on how cutting-edge analytical technologies are transforming the economics of battery recycling.

Looking for the video? Watch the recording of this session and more from Future Days: Battery Edition here.

Summary and Q&A

What happens when those batteries reach end-of-life? The answer represents both an environmental imperative and an economic opportunity. A typical 60-kilowatt EV battery contains substantial amounts of valuable metals – nickel, cobalt, and manganese – that justify sophisticated recovery processes when recycled properly.

The recycling process starts with crushing batteries to extract “black mass” – a heterogeneous powder containing all the valuable cathode materials. This black mass is where the money is, but its complexity demands smart analytical approaches to maximize recovery and profitability.

Malvern Panalytical’s multi-technology approach addresses this complexity through diverse analytical capabilities. X-ray fluorescence (XRF) handles versatile elemental analysis, Laser-Induced Breakdown Spectroscopy (LIBS) detects light elements like lithium that XRF misses, and Pulsed Fast Thermal Neutron Activation (PFTNA) provides in-line bulk analysis of entire containers, without sampling bias.

During their presentation, Rajendra and Michel showed how these technologies, when used in real-time and throughout the recycling workflow, transform recycling from reactive to predictive operations. Operators can track nickel, cobalt, and manganese concentrations throughout leaching and separation stages, enabling precise control that maximizes recovery while minimizing processing costs.

Below are key questions and answers from this session.

Q: Can you measure fluorine as well or do you also have a technology to screen for fluorine?

A: Yes, we can measure fluorine. As Michel mentioned in the presentation, when you need a more elaborate analysis of black mass that goes beyond the basic nickel, manganese, and cobalt measurements, you can determine fluorine content using our XRF instruments. Specifically, our Zetium instrument can detect whether there’s 1% or 5% fluorine present, and our Epsilon benchtop instruments can also handle fluorine analysis as part of comprehensive elemental characterization.

Q: Can you also measure lithium?

A: Absolutely. Lithium measurement requires LIBS (Laser-Induced Breakdown Spectroscopy) technology since XRF cannot detect light elements like lithium. We offer LIBS instruments in different configurations, including handheld forms for incoming goods screening and dedicated instruments specifically designed for checking lithium content in solutions during the recycling process.

Q: Can you measure the carbon content to understand caloric value in hydrometallurgical recycling?

A: Our multi-technology approach with XRF, LIBS, and PFTNA can handle various elemental analyses. For specific applications like carbon content measurement for caloric value assessment in hydrometallurgy processes, we would recommend discussing your particular requirements with our applications specialists to determine the most suitable analytical solution from our portfolio.

Watch the recording of this session and more from Future Days: Battery Edition here.

Further reading:

• Recap: Future Days Battery Edition 2025
• Future Days Battery Edition recap, part 1: Trends in battery production and materials
• Future Days Battery Edition recap, part 2: Emerging materials in electrochemical energy storage
• Future Days Battery Edition recap, part 3: Advanced analytics transforming battery recycling efficiency
• Future Days Battery Edition recap: Crystalline engineering revolutionizes solid-state micro batteries