A comprehensive techno-economic analysis of the full project for recycling valuable metals from waste Lithium-Ion battery

Efficient recycling of valuable metals from Lithium-Ion batteries (LIBs) is imperative for sustaining the supply of battery cathode materials and addressing environmental concerns. Despite a growing market and increased investments, a comprehensive analysis of full-scale projects remains elusive. This study conducts a comprehensive techno-economic assessment of the hydrometallurgical process for 3.9 t/h of waste NCM622 battery. Results show that 188 kg/h of MnO2, 330 kg/h of CoSO4, 919 kg/h of NiSO4, and 185 kg/h of Li2CO3 could be yielded by this process. The profitability is represented by the return on investment (ROI) of 22.2 % and net present value (NPV) of 726 M$. Sensitivity analysis of chemical, utility, and product costs is performed to identify their impact on profitability. The findings serve as valuable reference information for investment decisions in this burgeoning industry. [Display omitted] •A comprehensive techno-economic analysis of the hydrometallurgical process is evaluated for the industrial-scale plant.•All necessary sections such as Pretreatment, leaching, solvent extraction and purification are analyzed.•The analysis shows the process has economic feasibility.•The extraction section accounts for the highest percentage of investment cost.•The price of Li2CO3 has the greatest effect on the economical feasibility of the process.