Evaluating the sustainability of a pilot-scale spent lithium-ion battery recycling process

[Display omitted] This study presents a sustainability analysis of a pilot-scale process, integrating multiple technologies, designed to recover strategic metals from spent lithium-ion batteries (LIBs). The modularity of the proposed processes allows for a focused sustainability analysis of each technology as part of the overall recycling process, allowing for efficient evaluation and comparison of individual steps. The Evaluation of sustainability of material substitution using carbon footprint by a simplified (ESCAPE) approach combines simplicity and reproducibility of inventory, providing sufficient resolution to better evaluate the benefits and drawbacks of battery recycling options across various process categories. The results show that positive ESCAPE index values for lithium (Li) and cobalt (Co) are obtained. However, negative values are found for nickel (Ni) and manganese (Mn). The study also evaluates the differences in the sustainability of the proposed pilot across some European countries, accounting for variations in electrical energy mixes and material production footprints relevant to the considered regions. Results indicate that the proposed pilot plant has the potential to support a sustainable LIB value chain.