Sustainable method for disposing of ceramic-coated battery separator via carbon dioxide-assisted thermochemical process

The increasing demand for energy storage systems is driven by variability in renewable energy sources and the substantial energy requirements of electric vehicles. However, the typical 3–10-year lifespan of lithium-ion batteries raises concern about their disposal. The environmental challenges associated with conventional disposal and recycling methods (landfilling, incineration, and pyrometallurgical/hydrometallurgical processes) include the release of microplastics and air pollutants, such as volatile organic compounds, from plastic components. To address these issues, we propose a thermochemical process for managing plastic waste from discarded batteries, focusing on a separator from lithium-ion batteries as a model feedstock. Using carbon dioxide (CO₂) as a reaction medium enhances the sustainability of thermochemical processes. Specifically, co-feeding CO₂ at elevated temperatures (≥500°C) improves syngas and C_1–2-hydrocarbon production while reducing liquid pyrolysates. These reactions result from the partial oxidation of volatiles via gas-phase reactions with CO₂. Incorporation of CO₂ to optimize the conversion of battery separators into syngas represents an advancement toward the environmentally sound and efficient disposal of battery waste while yielding value-added products.