The increasing adoption of electric vehicles (EVs) has significantly accelerated the use of lithium-ion batteries (LIBs), creating an urgent need for efficient end-of-life (EOL) management strategies. This thesis focuses on two interconnected challenges: the recovery of valuable materials from spent EV batteries and the safe transportation of them after their operational life. It addresses the importance of safely transporting used (end-of-life) batteries, which are classified as Class 9 hazardous goods, due to risks such as thermal runaway and chemical leakage.

The study explores emerging direct recycling technologies, which offer a promising alternative to conventional pyrometallurgical and hydrometallurgical methods by preserving cathode structure and reducing energy consumption. It further evaluates the logistical and regulatory complexities of transporting spent LIBs, critically reviewing key international frameworks, including UN 38.3 (testing requirements for battery safety in transport), the European ADR (regulations for the international transport of dangerous goods by road applied specifically to used LIBs as hazardous cargo), and IATA DGR (for air transport).

The thesis assesses cost, risk, and compliance factors related to battery transport in global markets, including the EU, US, and China. Special attention is given to EU Regulation 2023/1542, which supports the circular economy by setting legal requirements for material recovery rates, recycled content in new batteries, and carbon footprint transparency.

This research aims to support more sustainable, efficient, and closed-loop systems for lithium-ion battery lifecycle management by integrating insights on direct recycling advancements and safe, regulation-compliant transportation.