Challenges and Innovations With Spent Battery Sorting

As the global reliance on batteries continues to expand, the need for efficient battery recycling has become increasingly pressing. Sorting plays a fundamental role in improving the recycling efficiency of downstream chemical processes by enabling classification based on battery forms, chemical compositions, and electrical parameters. However, sorting remains one of the most challenging aspects due to the lack of automation, a wide variety of battery chemistries, the complexity of forms and sizes, and inconsistent labeling practices. This review assesses the current battery sorting technologies, from manual and mechanical methods to advanced artificial intelligence (AI) driven solutions, along with regulatory challenges and emerging trends. The findings suggest two critical directions to enhance the role of sorting in future battery recycling: improving battery design for recyclability and developing automation integrated with deep learning for new sorting technologies.