Integrating sustainability across the lifecycle of electric vehicle batteries: circular supply chain challenges, innovations, and global policy impacts

This study investigates the integration of sustainability practices into the circular supply chain (SC) of electric vehicle (EV) batteries to address environmental and economic challenges. Using the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) protocol, a systematic review of 147 articles (2009–2024) identifies key challenges, solutions, innovations, and policy measures shaping the EV battery SC. The research uncovers 10 major challenges, 31 sub-challenges, and 160 detailed challenges, highlighting issues related to SC resilience, environmental impact, and economic sustainability. In response, 40 main solutions and 174 complete solutions are mapped, leading to the identification of 102 detailed technologies, 24 sub-technologies, and 8 core technologies supporting circular economy principles. These technologies are analysed for their long-term industry impact, with comparisons within categories to highlight their advantages, disadvantages, and contributions to circular economy goals. Additionally, global policy analysis reveals regulatory advancements, with China and the UK leading efforts to improve recycling, material recovery, and sustainability governance. This study also compares EV battery policies across countries using indicators like policy coverage, enforcement intensity, and effectiveness, highlighting their impact on sustainability and resource efficiency. A conceptual framework is developed to integrate these challenges, solutions, and innovations into a sustainable EV battery SC. The study concludes with theoretical insights, industry recommendations, and policy implications, offering a structured pathway toward sustainable and resilient EV battery SCs.