Reimagining Lithium Battery Recycling: A SimaPro-Based Life Cycle Assessment of Traditional and Innovative Approaches for Spent LIBs Recycling

The growing demand for electric vehicles (EVs) and the consequent increase in the use of lithium-ion batteries (LIBs) have created the need for efficient and environmentally responsible recycling solutions for spent LIBs. Current recycling technologies, such as pyrometallurgy and hydrometallurgy, involves high energy consumption, material usage, and hazardous waste generation. These challenges highlight the importance of developing innovative strategies to LIB recycling, aligned with sustainable development principles. The goal of this master’s thesis is to evaluate and compare the environmental impacts of three LIB recycling methods: pyrometallurgy, hydrometallurgy, and the AMELIE process, a novel approach proposed by the Università degli Studi di Brescia. This work study aims to assess the environmental sustainability of each process by evaluating energy requirements, material recovery rates, waste management, and environmental impacts, contributing to the development of greener recycling technologies. The methodology used for this work study is based on a Life Cycle Assessment (LCA) modelled in SimaPro software, conforming to ISO 14040 and ISO 14044 standards. The functional unit chosen was 1 kg of Black Mass (BM), with system boundaries set from “gate-to-grave” to focus on the end-of-life phase. Data for inputs and outputs of each process were sourced from both literature and experimental research. Environmental impacts were assessed through the ReCiPe (2016) method with a hierarchical approach and considering both midpoint and endpoint levels for result representation. The results of the LCA reveal that while pyrometallurgy is effective for large-scale recycling, is an energy-intensive process and results in material losses. Hydrometallurgy, through achieving higher recovery rates with lower energy use, has the disadvantages due to the wastewater it generates. The AMELIE process, which combine microwave-assisted thermal treatment with organic acid leaching, requiring less energy and have promising recovery rates. However, its biggest drawback is the environmental burdens resulting from the resource and energy-intensive production of the ascorbic acid. In conclusion, although pyrometallurgy and hydrometallurgy are established recycling methods, the AMELIE process demonstrates a promising potential as a sustainable approach for recycling LIBs if the ascorbic acid issue is addressed. It has the capacity to significantly reduce the environmental footprint of LIB recycling by recovering valuable metals to replace their primary production. Another important takeaway is the highlighting of the need for continuous innovation in recycling processes, the importance of sustainable development, and the critical role of LCA in guiding decision toward more sustainable practices.