India is on the cusp of an EV revolution-and along with it comes a deluge of spent lithium- ion batteries. According to NITI Aayog, the nation could produce over 200,000 tonnes of battery waste by 2030-posing both environmental risks and untapped resource opportunities.
This is more than just waste-it’s a reservoir of critical minerals like lithium, cobalt, nickel, and graphite, the lifeblood of battery production, currently sourced primarily through imports.
- The Promise of Global Innovation
Hydrometallurgy & Direct Recycling:
- Hydrometallurgy dominates modern recycling because of its efficiency and low emissions-recovering up to 95% of key materials compared to high-energy, emission-heavy pyrometallurgy.
- Direct recycling-where battery components are reconditioned rather than broken down-is gaining momentum in India.
European Breakthroughs:
- Altilium (UK) has partnered with Jaguar Land Rover; its recycled cathode materials reportedly deliver up to 70% lower CO₂ emissions and 20% lower cost than virgin alternatives.
- Tozero (Germany) is advancing hydrometallurgical graphite recycling, aiming for net-zero emissions and enough supply for 50,000 EVs by 2027.
North American Efforts:
- Redwood Materials, founded by Tesla co-founder JB Straubel, has achieved ~95% recovery of critical minerals, plans to produce 100 GWh of recycled cathode active material (CAM) annually by 2026-enough for 1.3 million EVs- and currently recycles over 70% of North America’s lithium-ion waste.
2. Where India Stands Today
Policy Foundation
- The Battery Waste Management Rules, 2022 introduced sweeping reforms- mandating Extended Producer Responsibility (EPR), setting collection targets (70% in 2023–24; 90% from 2026–27), and enabling battery traceability via CPCB’s centralized portal.
- These rules also prohibit landfill/ incineration, require refurbishment or recycling, and are a pivotal push toward formalizing the recycling sector.
Industry Activity & Capacity
- As of mid-2024, India’s annual lithium-ion battery recycling capacity stood at around 44,000 tonnes (~2 GWh)-but projections expect we’ll need to scale 60-fold to meet demand by 2030.
- Companies like Attero, Lohum, Exigo, Rubiman are developing ultra-refining facilities-yet their combined capacity remains modest.
- OEMs like Tata Motors, Mahindra Electric, Ola Electric, Hyundai, MG are increasingly collaborating with recyclers to establish reverse logistics and second- life battery programs.
Strategic Roadblocks
- High capital investment: Establishing end-to-end recycling plants costs ₹220–370 crores (~USD 26–45 million), while transporting spent batteries can add 35–50% to those costs.
- Fragmented infrastructure: The informal sector dominates collection, lacking safety or regulatory oversight.
- Technological & human resource gaps: Advanced processes like hydrometallurgy require R&D, automation, robotics, and skilled personnel-areas India is building capacity in but still lags.
3. A Vision for Circularity: India’s Strategic Playbook
| Pillar | Description |
| 3A: Circular Infrastructure Build- out | Kickstart regional recycling hubs to minimize logistics costs and scale operations. Leverage Gati Shakti logistics network for reverse flows. |
| 3B: Policy & Incentive Frameworks | Enhance BWMR with standardized battery designs, tax incentives for recycling tech, and PLI support for integrated recycling-manufacturing ecosystems. |
| 3C: Industry Collaboration | Encourage OEM-Recycler joint ventures and partnerships with global leaders like Altilium or Redwood to gain expertise and co-develop processes. |
| 3D: Technological & Workforce Enablement | Support deployment of hydrometallurgy and AI-driven disassembly, invest in R&D labs (e.g., via C-MET’s e-waste CoE), and launch skill development programs. |
| 3E: Digital Exploration & Traceability | Roll out the Battery Aadhaar, giving each battery a digital identity to enhance lifecycle tracking, SoH evaluation, and streamline recycling incentives. |
| 3F: Second-Life Applications | Scale the reuse of batteries with 60–70% capacity into energy storage, telecom infrastructure, or rural electrification- turning waste into resource. |
Conclusion
India’s EV future shouldn’t be linear-it must be circular. The technology is maturing globally, the policy foundation is laid, and multiple industry players are engaged. But success hinges on scale, coordination, and innovation.
By embracing hydrometallurgy, nurturing digital traceability like Battery Aadhaar, building formal recycling hubs, and forging international collaborations, India can turn a looming waste challenge into a strategic circular economy advantage-recovering over 90% of critical materials, reducing import dependency, generating green jobs, and setting global leadership in sustainable e-mobility.
👤 Satyendra Pal
EV Mobility Enthusiast | Enabling Sustainable Transport |DGM-Sales & Marketing, Evall Mobility Ltd
