Fostering lithium-ion battery remanufacturing through Industry 5.0

The rise of electric vehicles (EVs) has resulted in notable environmental benefits, yet challenges persist regarding battery disposal and recovery. The increasing demand for EVs heightens concerns about the environmental impact of lithium-ion battery (LIB) waste, which threatens both ecosystems and public health. Although remanufacturing is seen as a sustainable solution to these issues, current research does not thoroughly examine the role of Industry 5.0 technologies in optimising this process. This study aims to compare and assess the potential of various Industry 5.0 technologies and approaches to enhance the remanufacturing of lithium-ion batteries. Using the AHP-PROMETHEE method, we identify the most critical and influential Industry 5.0 prospects that should be prioritised for addressing key challenges such as diagnostic accuracy, safe disassembly, and high-quality reassembly. The multi-criteria analysis highlights key Industry 5.0 imperatives that can facilitate efficient and effective remanufacturing processes. The study identifies Digital Product Passport (DPP), Digital Twin (DT), and the Internet of Everything (IoE) as critical enablers in optimizing the LIB remanufacturing process. The analysis reveals that DPP stands out as the top enabler, significantly enhancing transparency, traceability, and lifecycle management for LIBs. DT and IoE follow closely, contributing to real-time monitoring, predictive maintenance, and seamless data integration across the supply chain. This paper delves in the emerging concept of the Digital Battery Passport (DBP), a DPP mandated by recent European regulations aimed at improving battery management and circularity. The DBP facilitates access to critical data throughout the battery's lifecycle, including its origin, composition, and state of health. This information is crucial for optimising remanufacturing processes, ensuring compliance with sustainability standards, and extending battery life. The paper highlights the potential of DBP to transform the EV battery value chain by enhancing transparency and enabling more informed decision-making across stakeholders. Our findings offer significant insights for policymakers, battery manufacturers, and remanufacturing firms.