The recycling of retired lithium-ion batteries (LIBs) is conventionally achieved through pyrometallurgical or hydrometallurgical approaches, which require substantial energetic and procedural efforts to achieving an effective separation of materials with a desired high degree of purity. An alternative approach is the direct recycling, which can be considered a distinct methodological shift. In contrast to other approaches, the disassembly process for direct recycling extends to the electrode level, including the dismantling of electrode-separator-composite and ensuring a high level of purity while enabling regeneration of the active materials. However, currently available process chains regarding for direct recycling require manual cell disassembly, posing challenges related to both safety and process efficiency. Systematic studies for an automation of cell disassembly processes remain very limited. The present research addresses this gap by exploring a conceptual framework for automated cell disassembly and aims to identify key steps and associated parameters. A range of commercial retired battery cells are analyzed, utilizing computer tomography (CT) scan technology to identify internal cell structures and joints. This provides useful information for developing appropriate cell disassembly processes. The cells are subsequently dismantled manually for post-mortem analysis. Building upon the understanding from the CT scan and post-mortem analysis, a reverse production process flow is devised to disassemble the cell down to the electrode level.
Based on the disassembly process and its evaluation through morphological analysis, a complete conceptual framework in cell and electrode levels is developed, with key parameters for each step and potential tools along with methods outlined for future studies. Further investigations related to the specified parameters could be conducted using a single disassembly unit within a controlled environment. Additionally, concepts for interconnected disassembly units would be feasible, which allow for studying of selected disassembly steps collectively in a disassembly station. Moreover, all stations could be integrated to establish a comprehensive automated disassembly line within a closed environment. The conceptual framework derives a design of a prototype disassembly station for further experimental study, contributing to the development of effective pretreatment processes for direct recycling of LIBs.