The recycling rates in India have been rising over the past five years, still 67% of e-waste remains unprocessed. Data from the Central Pollution Control Board (CPCB) indicates that only 33% of India’s total e-waste generated in 2021-22 was collected and processed. Reportedly, out of the 16.01 lakh tonnes of e-waste generated, only 5.27 lakh tonnes were collected and processed. As of 2023, reports point out, India has 567 e-waste processing facilities with a total capacity of around 17.23 lakh tonnes annually, including 208 recycling facilities with a combined capacity of 10.69 lakh tonnes annually. Haryana topped the list of states for e-waste collection and processing, handling 2.45 lakh tonnes in 2021-22.
Source: statista.com
Despite slow progress, proper e-waste handling is vital for reducing environmental impact.
Cutting-edge technologies
Technology advancements have greatly improved battery and e-waste processing. The traditional e-waste recycling process, involving dismantling, shredding, and material separation and extraction, is being enhanced by cutting-edge technology.
Hydrometallurgy is one of the most efficient e-waste recycling technologies in India, says Rajesh Gupta, Managing Director, Evergreen Recyclekaro (India) Pvt Ltd. “We use this process at our waste recycling facilities and achieve an extraction efficiency of around 95%” He also adds that the ultrasonic battery disassembly technology, although not widely implemented yet, has a great scope in the future.
Shubham Vishvakarma, Founder and Chief of Process Engineering, Metastable Materials, shares, “The primary methods of battery recycling are hydrometallurgy, pyrometallurgy, and new on the scene, direct recycling and integrated carbothermal reduction." While the former method retains the structure of the lithium-ion battery cathode rather than going through materials dissolution and repurification, the latter "is a chemical-free form of recycling battery waste (successfully implemented at a pilot scale).”
Vishvakarma also highlights the impact of artificial intelligence (AI) on e-waste recycling. “AI-powered sorting systems with advanced image recognition accurately identify and categorise e-waste, improving material recovery efficiency. X-ray fluorescence (XRF) technology, combined with AI, analyses the elemental composition of e-waste, enhancing the recovery of valuable metals like gold, copper, and rare earth elements. Additionally, bio-remediation, which uses microorganisms to break down hazardous materials, offers a cleaner, more sustainable alternative to traditional chemical treatments.” Although mostly at the lab level, these innovations demonstrate significant progress in e-waste recycling.
Two major technologies stand out for Anupam Kumar, CEO and Co-founder, MiniMines. He speaks about electrowinning or electroplating and solvent extraction. “Electrowinning recovers metals like nickel, while solvent extraction achieves selective metal recovery using organic solvents.” Furthermore, MiniMines has developed its patented process – Hybrid Hydrometallurgy TM. Currently, tailored for lithium-ion batteries, it can also be optimised for e-waste in the future. This includes three key segments: Extraction, selective separation, and beneficiation. As Kumar explains:
“Extraction: All metals present in the graphite lattice structure of the batteries are removed and dissolved into a single solution media.
Selective separation: In this critical step, specific additives are used to selectively precipitate and separate cobalt, nickel, lithium, and manganese from the solution at different conditions, akin to a distillation process.
Beneficiation: This step purifies the recovered minerals to 99.9% purity, making them suitable for various industrial applications.”
The process starts by safely discharging lithium-ion batteries using a proprietary solution to stabilise them and aid complete lithium recovery. The recovered materials can then be integrated into cathode active materials for new battery manufacturing, completing the recycling loop.
Gaurav Dolwani, Founder & CEO, LICO Materials, notes India’s robust collection systems, particularly from auto OEMs and battery pack manufacturers, is leveraging the country’s metallurgical expertise. LICO Materials plans to refine black mass into metal salts using hydrometallurgy, aiming to scale up to a plant capable of processing 10,000 metric tonnes of black mass equivalent to 20,000 batteries annually, with an estimated 18 to 24 months for construction.
E-waste tracking systems
E-waste tracking systems are playing a crucial role in ensuring responsible recycling practices.
“These systems leverage technologies like Radio Frequency Identification (RFID) tags and blockchain to monitor the movement and disposal of electronic waste throughout its lifecycle,” says Vishvakarma. This data provides valuable insights for organisations, enabling them to:
- Identify patterns: By analysing e-waste movement patterns, organisations can pinpoint areas with high waste generation and optimise collection strategies.
- Track recycling efforts: E-waste tracking allows organisations to monitor the efficiency of their recycling processes and identify areas for improvement.
- Ensure compliance: Real-time data tracking helps organisations stay compliant with evolving e-waste regulations and prevent illegal disposal practices.
The benefits extend beyond organisational efficiency. As Vishvakarma shares, “E-waste tracking helps minimise environmental pollution by preventing illegal dumping and improper disposal. Additionally, it promotes transparency and accountability within the recycling industry, fostering trust with consumers and regulators.”
Dolwani says, “We have a portal and an app that track each shipment coming back to our facilities, using geotagging and timestamping. Each shipment receives unique codes for traceability from collection to processing, ensuring transparency, particularly with vehicle OEM partners, and providing vital information on the material’s journey.”
India ranks as the world's third-largest e-waste producer, annually generating 1.71 million metric tonnes, with only around 40% recycled in the last fiscal.
To address this challenge, the EPR portal by the CPCB provides a transparent framework for e-waste management in India. “It centralises e-waste tracking from production to disposal, connects manufacturers with registered recyclers and streamlines collection and recycling processes,” says Gupta. “The system offers financial incentives through EPR credits, making recycling economically viable and supporting companies in meeting sustainability targets. Additionally, it ensures regulatory compliance, improves data collection and reporting, and encourages innovation in recycling technologies, fostering a more sustainable approach to e-waste management in India.”
Gupta adds that the Battery Waste Management (BWM) Rules, 2022, notified by the Ministry of Environment, Forest, and Climate Change, apply to all battery types. These rules mandate that producers (manufacturers, importers) meet collection and recycling targets for Extended Producer Responsibility (EPR).
Implemented in 2024, the policy requires OEMs to identify end-of-life instruments, collect, and segregate battery waste, and deliver them to respective recyclers.
“This initiative aims to create a transparent reverse supply chain for waste batteries,” says Kumar. However, he adds that if the system is weak, it can lead to significant losses, such as the illegal export of lithium-ion batteries, causing India to lose valuable resources like cobalt, nickel, and lithium. Since India lacks commercial ores of these metals, waste batteries are crucial. To address this, he suggests a stronger tracking system. The “battery passport” concept is being introduced to trace products back to their origin and track their lifecycle for proper recycling. India should adopt this initiative.
Bridging the e-waste processing gap
India’s e-waste gap is shrinking owing to tech. “Automated sorting systems with robots are speeding up and improving material separation,” says Gupta. Even in the battery space, particularly lithium-ion batteries, it is continuously evolving. Hence, the recycling process must also evolve continuously.
Kumar says that the recycling process should meet three main criteria: better unit economics for commercialisation, sustainability, and the ability to produce finished products for practical applications or end use application, thereby closing the loop for these critical metals.
Vishvakarma stresses the need for innovative strategies to manage the rapid rise in e-waste generation, highlighting technology’s crucial role. “Urban mining extracts valuable resources from discarded electronics, promoting a circular economy and reducing reliance on new resources. Modular designs for electronics simplify recycling by allowing easier disassembly and component replacement, extending product lifespan. EPR policies hold manufacturers accountable for product lifecycle, encouraging designs that are easier to recycle. Efficient transportation and collection systems, aided by smart logistics tools, optimise routes, cutting costs and improving efficiency.”
Future of e-waste tech in India
As electric vehicles (EVs) surge, lithium-ion battery recycling will gain importance. And India targets a major recycling capacity boost by 2030. “Using previously existing technology which were used for aiding uranium and plutonium separation is not directly applicable to lithium, cobalt, and nickel recovery necessitating cost-effective alternatives,” says Kumar. “Addressing e-waste, emerging chemistries like sodium-ion batteries, and varying battery types is crucial.”
Dolwani sees the next decade as pivotal for India’s e-waste and battery recycling sector, emphasising the need for flexibility and evolution. “With emerging chemistries like high nickel batteries and LMFP, adaptability is key.”
Absolutely! The future of India’s e-waste and battery recycling sector hinges on innovation, policy support, and collaboration. Strengthening ties between industry, government, and academia is crucial for advancing research, while supportive government policies promoting investment in advanced recycling technology are essential for a sustainable e-waste management system.