4 May 2026

Characterizing Lithium-Ion Battery Health and Mitigating Transportation and Recycling Hazards

Abstract: With the growing trend toward electric vehicle (EV) use, the demand for safe, efficient, and cost-effective energy storage grows increasingly crucial. The ability to effectively characterize battery health, transport and dispose of batteries safely, and mitigate the by-products of battery recycling are all important to reduce the risks of lithium-ion battery (LIB) usage throughout the battery’s life cycle. The transportation and disposal of LIBs present critical challenges and require stringent safety measures to mitigate risks effectively. Additionally, many recycling methods are less cost-effective or more environmentally harmful than mining new materials. This report describes the findings of a collaborative project between the University of Illinois Urbana-Champaign and US Army Engineer Research and Development Center, Construction Engineering Research Laboratory, to address these concerns and contribute to safer and more environmentally friendly transportation, recycling, and disposal of LIBs. The most common battery recycling techniques are investigated—pyrometallurgy, hydrometallurgy, and direct recycling—along with the environmental impact of these methods. The overall potential environmental impacts of LIB usage can be greatly improved through proper battery disposal. Addressing hazards at the battery level by enhancing the stability and cooling of batteries can simplify battery transportation and improve safety.