Sustainability Analysis of Processes to Recycle Discharged Lithium-Ion Batteries, Based on the ESCAPE Approach

There are several recycling methods to treat discharged lithium-ion batteries, mostly based on pyrometallurgical and hydrometallurgical approaches. Some of them are promising, showing high recovery efficiency (over 90%) of strategic metals such as lithium, cobalt, and nickel. However, technological efficiency must also consider the processes sustainability in terms of environmental impact. In this study, some recycling processes of spent lithium-ion batteries were considered, and their sustainability was evaluated based on the ESCAPE “Evaluation of Sustainability of material substitution using CArbon footPrint by a simplifiEd approach” approach, which is a screening tool preliminary to the Life Cycle Assessment (LCA). The work specifically focuses on cobalt recovery comparing the sustainability of using inorganic or organic acid for the leaching of waste derived from lithium-ion batteries. Based on the possibility to compare different processes, for the first time, some considerations about technologies optimization have been done, allowing proposing strategies able to save chemicals. In addition, the energy mix of each country, to generate electricity has been considered, showing its influence on the sustainability evaluation. This allows distinguishing the countries using more low-carbon sources (nuclear and renewables) for a share of the electricity mix, where the recycling processes result more sustainable. Finally, this outcome is reflected by another indicator, the eco-cost from the virtual pollution model 99′ proposed by Vogtländer, which integrates the monetary estimation of carbon footprint.