Batteries From Reused, Recycled, and Surplus Materials

ABSTRACT

The integration of reused batteries, reconditioned components, and recycled or surplus materials into current and next‐generation energy storage technologies is increasingly driven by environmental concerns, resource scarcity, regulatory pressures, and economic incentives. While the volume of end‐of‐life batteries available for recycling remains insufficient to meet rapidly rising demand, secondary feedstocks from outside the battery sector, including biomass‐derived resources and residues from metallurgy, electronics, and oil refining, are increasingly viewed as complementary supply options. However, their deployment is constrained by the ability to meet battery‐grade purity specifications, which are chemistry‐dependent and strongly influence process feasibility and cost. This review summarizes recent progress, persistent bottlenecks, and practical strategies to build a more resilient and sustainable battery materials supply chain. We survey repurposing, refurbishment, and recycling approaches across material, component, cell, and pack levels; assess alternative feedstock routes; and discuss sustainable‐by‐design principles, economic and environmental impacts, regulatory drivers, life‐cycle assessment, recycling viability, and traceability tools such as the battery passport. Together, these perspectives outline actionable pathways to accelerate circular, scalable, and compliant battery manufacturing.