A Review of Fire and Explosion Hazards in Sustainable Lithium-Ion Battery Recycling Industries

The extensive integration of lithium-ion batteries (LIBs) into modern technologies—including portable electronics, electric vehicles (EVs), and battery energy storage systems (BESSs)—has created a critical dependency on the supply of raw materials. The ongoing shift toward clean mobility is expected to further intensify this demand. This trend coincides with a projected increase in battery waste: over the next decade, millions of tons of EV and BESS batteries will reach their end-of-life (EOL), alongside the generation of considerable manufacturing scrap. Recycling is essential for recovering critical materials and reducing dependency on primary mining, thereby benefiting the circular economy and environmental sustainability. However, EOL-LIBs are more prone to thermal runaway due to defects and aging-induced degradation, which can lead to fire and explosion incidents, as well as associated environmental and health hazards. Such incidents have been increasingly reported in recent years during transportation, storage, handling, and illegal disposal, resulting in potential loss of life, property damage, and ecological degradation. To ensure the safe design and operation of the battery recycling industry, this work provides an updated overview of the health, safety and environment (HSE) hazards posed by EOL-LIBs and the safety measures required to mitigate these hazards. First, this work outlines the structures, components, and aging mechanisms of LIBs. Second, it summarizes the state-of-the-art recycling pathways and relevant process risks, such as deactivation, dismantling, and mechanical and thermal pretreatments. Third, it reviews recent safety incidents initiated by thermal runaway of EOL-LIBs and recycling intermediates like black mass, with an emphasis on storage and handling. Fourth, recommendations for future work regarding the safe storage and processing of EOL batteries are provided. Finally, conclusions and perspectives on future research directions are presented. Continued research and development in this field are essential to improve recycling methods, optimize processes, and ensure the safe and sustainable management and legislation of EOL lithium-ion batteries.