It remains the dominant route, especially for lead-acid batteries, and is widely used for lithium-ion too. Its weak point is lithium: in most smelting processes it ends up in the slag. With EU rules requiring 50% lithium recovery by the end of 2027, that gap is becoming hard to ignore.

Why pyrometallurgy still leads

• Feedstock flexibility: it handles mixed battery types and chemistries with minimal sorting.
• Mature infrastructure: it builds on existing smelting capacity.
• Scale economics: lower deployment costs at large sites.

Smelting recovers cobalt, nickel and copper efficiently as metal alloys. Lithium, aluminium and manganese, however, typically report to the slag, where recovering them economically is very difficult.

Battery recycling methods compared

What the EU Battery Regulation requires

Regulation (EU) 2023/1542 sets minimum material recovery targets for waste batteries:

• Lithium: 50% by the end of 2027 and 80% by the end of 2031.
• Cobalt, nickel, copper and lead: 90% by the end of 2027 and 95% by the end of 2031.
• Recycling efficiency for lithium-based batteries: 65% by the end of 2025 and 70% by the end of 2030 (by average weight).

Smelting alone cannot meet the lithium targets. As a result, the industry is moving towards combined flowsheets: mechanical pre-treatment, hydrometallurgical refining and, increasingly, direct recycling.

Where the market is heading

Grand View Research expects hydrometallurgy to be the fastest-growing recycling method, at a 41.3% CAGR from 2026 to 2033, driven by regulation and by lithium's status as a strategic raw material.

At Wastes Service Group, we are actively researching battery recycling processes, including hydrometallurgical and direct recycling solutions, alongside our collection, transport and recycling services for spent batteries. Get in touch to discuss collaboration or recycling solutions.

FAQ

What is the difference between pyrometallurgy and hydrometallurgy?

Pyrometallurgy recovers metals by high-temperature smelting; hydrometallurgy uses chemical leaching and selective separation in aqueous solutions. Hydrometallurgy can recover lithium; smelting largely cannot.

What is direct recycling?

A method that recovers and regenerates cathode material without breaking it down into individual elements, preserving its value and reducing energy use.

How much lithium must be recovered from batteries in the EU?

At least 50% by the end of 2027 and 80% by the end of 2031, under Regulation (EU) 2023/1542.