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A Material Flow Analysis of Electric Vehicle Lithium-ion Batteries: Sustainable Supply Chain Management Strategies

Author

Listed:
  • Hyeong-Jin Choi

    (Resource Recirculation Research Division, National Institute of Environmental Research, Incheon 22689, Republic of Korea)

  • Minjung Kim

    (Emerging Waste to Resource Research Division, National Institute of Environmental Research, Incheon 22689, Republic of Korea)

  • Hyung Joo Roh

    (Program in Circular Economy Environmental System, Graduate School, Inha University, Incheon 22212, Republic of Korea)

  • Donggun Hwang

    (Emerging Waste to Resource Research Division, National Institute of Environmental Research, Incheon 22689, Republic of Korea)

  • Young-Sam Yoon

    (Resource Recirculation Research Division, National Institute of Environmental Research, Incheon 22689, Republic of Korea)

  • Young-Yeul Kang

    (Resource Recirculation Research Division, National Institute of Environmental Research, Incheon 22689, Republic of Korea)

  • Tae-Wan Jeon

    (Resource Recirculation Research Division, National Institute of Environmental Research, Incheon 22689, Republic of Korea)

Abstract

The increasing adoption of electric vehicles (EVs) has highlighted the need for sustainable lithium-ion battery (LIB) management. This study presents a material flow analysis (MFA) of EV LIBs in the Republic of Korea (RoK), using both a mass-based MFA and a substance flow analysis (SFA). The analysis defines 33 systems and 170 flows across the manufacturing, consumption, discharge and collection, and treatment stages, based on national statistics and data from 11 commercial facilities. In 2022, about 72,446 t of EV LIBs entered the consumption stage through new vehicle sales and battery replacements. However, domestic recovery was limited, as approximately 76.5% of used EVs were exported, reducing the volume of batteries available for recycling. The SFA, focusing on nickel (Ni), cobalt (Co), manganese (Mn), and lithium (Li), showed recovery rates of 69% for Ni, 80% for Co, 1% for Mn, and 80% for Li. Mn was not recovered because its low market price made the recovery process economically impractical. Additional losses occurred from the incineration of separators containing black mass and lithium discharged through wastewater. These findings offer data-driven insights to improve recovery efficiency, guide policy, and enhance the circularity of EV LIB management in the RoK.

Suggested Citation

  • Hyeong-Jin Choi & Minjung Kim & Hyung Joo Roh & Donggun Hwang & Young-Sam Yoon & Young-Yeul Kang & Tae-Wan Jeon, 2025. "A Material Flow Analysis of Electric Vehicle Lithium-ion Batteries: Sustainable Supply Chain Management Strategies," Sustainability, MDPI, vol. 17(10), pages 1-18, May.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:10:p:4560-:d:1657434
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    References listed on IDEAS

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    1. Littlejohn, Christina & Proost, Stef, 2022. "What role for electric vehicles in the decarbonization of the car transport sector in Europe?," Economics of Transportation, Elsevier, vol. 32(C).
    2. Liu, Wei & Li, Xin & Liu, Chunyan & Wang, Minxi & Liu, Litao, 2023. "Resilience assessment of the cobalt supply chain in China under the impact of electric vehicles and geopolitical supply risks," Resources Policy, Elsevier, vol. 80(C).
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    1. Oluwatosin S. Atitebi & Erick C. Jones, 2025. "Centralized vs. Decentralized Black-Mass Production: A Comparative Analysis of Lithium Reverse Logistics Supply Chain Networks," Logistics, MDPI, vol. 9(3), pages 1-18, July.

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