On this page
- Introduction
- What are the new CPCB Guidelines for Lithium Ion Battery Recycling?
- Lithium-Ion Battery Recycling Process
- Infrastructure Required for Lithium-Ion Battery Recycling
- Pollution Control and Environmental Requirements
- Emission Standards for Lithium-Ion Battery Recycling
- Worker Safety Requirements
- EPR Registration and Compliance
- Records and Returns to Maintain
- What Happens in Case of Non-Compliance?
- How to Set Up a Lithium-Ion Battery Recycling Plant in India
- Key Takeaways from the July 2026 Guidelines
- Conclusion
Introduction
The application of Lithium ion battery technology can be found in the automotive, energy storage, consumer electronics, and other sectors. With an increasing number of used batteries, their recycling is becoming a necessity to recover beneficial metals such as lithium, cobalt, nickel, copper, and aluminum from the batteries without polluting the environment.
The Central Pollution Control Board (CPCB), under the Ministry of Environment, Forest and Climate Change, has released some guidelines on recycling of Waste Batteries (Lead Acid and Lithium-ion) in July 2026.
What are the new CPCB Guidelines for Lithium Ion Battery Recycling?
The new CPCB guidelines of July 2026 lay out a sustainable method for the recycling of lithium-ion batteries.
The recycling process includes infrastructure, safety, disassembling, shredding, black mass separation, hydrometallurgy, pollution control and emissions monitoring and record keeping.
According to CPCB guidelines, the processes of lithium-ion battery recycling are categorized as follows:
- R2: Dismantling & physical separation of batteries up to black mass.
- R3: Treatment of black mass to recover metal compounds.
- R4: Dismantling & physical separation of batteries up to treatment of black mass.
These guidelines apply to batteries that are not lead acid batteries.
Lithium-Ion Battery Recycling Process
Collection and handling of waste batteries are the first steps in the recycling process. The value chain may involve collecting, transporting, handling, discharging, storing, sorting, inspection, dismantling and processing or metals or metal salts recovery.
1. Collection and Transportation
Waste batteries of lithium-ion type should reach the recycling facility through proper collection techniques. Lithium-ion batteries can be collected from customers, traders, manufacturers, collectors or other authorized sources. For businesses involved in importing waste batteries, understanding how to import used lithium-ion batteries for recycling is also important from a regulatory compliance perspective.
The transportation process needs to be managed carefully since damaged or charged batteries of this kind are known to pose fire hazards.
2. Safe Storage and Sorting
Proper spaces for storing batteries of different kinds of lithium-ion batteries need to be provided in the recycling facility. Fire fighting facilities like fire hydrants, sprinklers and suitable extinguishers should be available at the places of storage and usage.
Then, sorting should take place in accordance with their kind, size and chemical composition. Batteries that might require refurbishment or second usage can be distinguished from those requiring recycling.
3. Discharge of Batteries
Prior to dismantling, batteries of lithium-ion should be discharged properly. CPCB guidelines provide different ways of discharging such as dynamic or static resistance using an electronic load or an alkaline solution. Measurement of voltage should be conducted either before or during the dismantling process.
Temperature measurement is also suggested to identify abnormal cells. Such cells need to be segregated and kept under constant surveillance.
Discharge tanks using a salt solution or any other discharge facilities are also recommended by the guidelines.
4. Disassembly
Now that the battery has been discharged, the battery pack can be disassembled. Many external components such as the casing of the batteries, battery management system, power electronics, plastic, cables, and others are stripped off.
Large battery packs could be broken down to modules and cells so that handling and processing would be easy.
Provisions for fire prevention and other safety considerations need to be made because lithium-ion batteries are dangerous due to mechanical hazards, flammability, and thermal runaway.
5. Crushing and Shredding
After disassembling and discharging, the batteries are sent to the crushing/shredding machine.
An explosion-proof electrical system should be included in the design of the shredding system along with adequate guards for the safety of the personnel. The feeding rates need to be automatically regulated so that overfeeding does not occur. Temperature controls need to be provided in the shredding and drying units.
The shredding results in mixed output comprising the following materials:
- Aluminium
- Iron
- Copper
- Plastics
- Black mass
Control of electrolyte needs to be exercised as well during the process.
6. Separation of Metals and Black Mass
A magnetic/density separator can be employed to separate iron, copper, aluminium, and plastics from the black mass.
According to CPCB guidelines, proper pollution control systems such as suction hoods, cyclones, and pulse-jet bag filters should be provided to prevent black mass dispersion during the separation process.
Black mass is very important since it comprises material that can be further processed to recover critical metals.
Hydrometallurgical Processing of Black Mass
Hydrometallurgical process is one of the most important techniques described in CPCB guidelines for recovering metals and metal salts from lithium-ion batteries black mass.
This process is performed by treating black mass with a variety of chemical agents, including acids and water, in a reactor, which operates at certain pH and temperature values. The leachate is thereafter separated from the solid. The liquid component is then subjected to purification and solvent extraction processes that aid in separating the valuable metals such as manganese, cobalt, nickel, and lithium. This process can be used to produce metal salts like sulphates and carbonates.
CPCB guidelines reveal that there are a number of techniques that may be used in the extraction of useful elements, including pyro-metallurgy, hydrometallurgy, and electrochemical techniques.
Infrastructure Required for Lithium-Ion Battery Recycling
Based on the function the compliant recycling plant is required to perform, different types of facilities can be required to perform that particular function.
Some of these facilities are:
- Battery storage facilities
- Fire hydrants and sprinklers
- Suitable fire extinguishers
- Battery discharging facilities
- Drying facilities and conveyors
- Shredders/ crushers
- Flame proof electrical fittings
- Magnetic and density separation facilities
- Facilities for black mass storage
- Leaching reactors
- Filtration units
- Extraction reactors
- Stripping units
- Centrifuge and drying facilities
- In some cases evaporation and crystallization facilities
- Pollution control facilities
- Effluent treatment plants (ETP)
- Stacks appropriately stacked and monitored
The facilities that fall within the guidelines of hydrometallurgical facilities are leaching reactors, filtration units, extraction reactors, stripping units and suitable drying facilities.
Pollution Control and Environmental Requirements
Pollution control forms a very essential component of the lithium-ion batteries recycling process. The black mass management process must be done under enclosed structures with air pollution control facilities.
The recommendations state that controls such as bag filters should be installed for particulates, alkaline scrubbers for acidic fumes and fume extraction system followed by activated carbon filters for the VOC emissions from the solvent extraction plant. Good ventilation must also be provided.
Waste water from processing, floor cleaning, spills, reactor cleaning, scrubber bleed and others should be either recycled or treated physically and chemically in ETP as per applicable norms.
Emission Standards for Lithium-Ion Battery Recycling
The CPCB guidelines specify source-emission standards for parameters including particulate matter, manganese, sulphuric acid mist, total fluoride, hydrogen fluoride and total organic carbon.
For example, the listed source-emission limits include:
| Parameter | Standard |
|---|---|
| Particulate Matter | 50 mg/Nm³ |
| Manganese as Mn | 5 mg/Nm³ |
| Sulphuric Acid Mist | 50 mg/Nm³ |
| Total Fluoride | 25 mg/Nm³ |
| Hydrogen Fluoride | 4 mg/Nm³ |
| TOC | 20 mg/Nm³ |
The guidelines state that the applicable standard is the specified standard or the limit prescribed by the concerned SPCB/PCC, whichever is more stringent.
Monitoring of specified source and work-zone emission parameters is to be conducted quarterly during the first year and at least annually thereafter. Testing is to be undertaken through ISO 17025-accredited or EPA-approved laboratories, with results submitted to the concerned SPCB/PCC according to the Consent to Operate conditions.
Worker Safety Requirements
There are some dangers in connection with recycling of the lithium-ion battery, which are the following: electrical, chemical, fire and occupational hazards. Some safety precautions have to be taken in respect of fire extinguishing, protecting electrical devices from fire, ventilation and personal protective equipment (PPE).
If employees work with any hazardous substance, they have to wear PPE as it is recommended in MSDS. Another important issue related to dealing with the battery is that it can be in an unusual state due to different temperatures and charges.
EPR Registration and Compliance
Recycling does not just mean following the procedures involved in the recycling process. According to the guidelines, the recyclers should register themselves at the online EPR portal for Battery Waste Management which is developed by CPCB.
According to the guidelines, the recyclers should be in a position to document the entire process of procurement of waste batteries, their recycling and sales of recycled materials. The recyclers should also ensure that EPR certificates are generated for the producers to help them comply with EPR guidelines.
Therefore, when it comes to lithium-ion battery recycling, EPR compliance has to be considered.
Records and Returns to Maintain
The recycling plant must have the following appropriate records regarding:
- Procured waste batteries
- Recycled batteries
- Sold recovered materials
- Generated EPR certificates
- Transfer of EPR certificates to producers
- Quarterly EPR reporting
- Environmental monitoring
- Wastewater treatment and disposal
- Pollution control systems
Proper record keeping is necessary for ensuring compliance with the Battery Waste Management system.
What Happens in Case of Non-Compliance?
Violation of the CPCB guidelines would attract measures in accordance with the Environment Compensation Guidelines issued under the Battery Waste Management Rules, 2022.
In particular, the July 2026 guidelines indicate that violations will be dealt with in accordance with the Environment Compensation Guidelines under the Battery Waste Management Rules, 2022, released in September 2024.
Where there is environmental damage due to inappropriate handling, including any spills in the course of generation, storage, processing, transportation, or disposal of batteries, then the responsible occupier may have to conduct an immediate response and environmental remediation.
How to Set Up a Lithium-Ion Battery Recycling Plant in India
Any organization considering the construction of a lithium-ion battery recycling factory must view this as an industrial and compliance venture.
The entire process entails:
Business Planning → Technology Selection → Plant Design → Pollution Control Planning → Regulatory Approvals/Consents → CPCB EPR Registration → Equipment Installation → Safety → Trial/Operation Compliance → Recycling/Materials Recovery → EPR Reporting
The specific regulations would be dependent on the recycling category, technology, capacity and operations at the recycling plant.
Key Takeaways from the July 2026 Guidelines
Safety during discharge, dismantling, fire prevention, pollution management, handling of black mass, metal recovery, occupational safety, and EPR tracing have all become very essential due to the guidelines by CPCB.
Regarding the lithium-ion battery recyclers, the compliance should not just be considered in terms of the use of the shredding machine and black mass collection but also facilities, safety measures, pollution management, environmental monitoring, and EPR tracing.
In addition, the guidelines state that they are in addition to the 2025 guidelines on the utilization of black mass for the recovery of carbon and graphite as well as metal compounds through hydrometallurgy.
Conclusion
Battery recycling in lithium-ion has become a significant part of the circular economy in India. July 2026 CPCB guidelines provide a comprehensive structure from collection of waste lithium-ion batteries till discharge, dismantling, shredding, black mass separation, and hydrometallurgy.
In case of new companies in the industry, the following aspects must be considered by them: environment-friendly process, fire, and safety, pollution control equipment, environmental clearances, EPR registration, traceability, and returns.
A recycling facility that is effective and meets the above criteria will help in higher recovery rates and lesser risks associated with the waste batteries.
Frequently asked questions
What are the new CPCB guidelines for lithium-ion battery recycling in India?
The July 2026 CPCB guidelines provide a structured approach to lithium-ion battery recycling, covering collection, safe storage, discharge, dismantling, shredding, black mass separation, metal recovery, pollution control, worker safety, emissions monitoring, and EPR compliance.
What infrastructure is required for a lithium-ion battery recycling plant?
A recycling plant may require battery storage and discharge facilities, fire hydrants and sprinklers, suitable fire extinguishers, shredders and crushers, magnetic and density separation systems, black mass storage, leaching reactors, filtration and extraction units, drying facilities, pollution control systems, and an effluent treatment plant (ETP).
Is EPR registration required for lithium-ion battery recyclers?
Yes. According to the July 2026 CPCB guidelines, lithium-ion battery recyclers should register on the online EPR portal for Battery Waste Management developed by CPCB. They also need to maintain records of waste batteries procured and recycled, recovered materials sold, EPR certificates, environmental monitoring, and related compliance activities.
