Life Cycle Assessment of an Innovative Process Assisted by Pressurized CO₂ for Direct Recycling of Lithium-Ion Battery Positive Electrode Production Scraps

With global lithium-ion battery (LIB) production on the rise, production scraps, constituting 5 to 30 wt % of the total manufacturing output are expected to remain a major waste stream until at least 2030. These scraps present a significant recycling challenge, necessitating the development of effective and sustainable solutions. In this study, we conduct a life cycle assessment (LCA) of an innovative CO2-assisted direct recycling process for LIB-positive electrode production scraps. Using NMC622 (LiNi0.6Mn0.2Co0.2O2) positive electrode material as a case study, this paper describes the environmental benefits and impacts of the recovery of this material with direct recycling compared to other conventional treatments (incineration, pyrometallurgy, and hydrometallurgy). Lab-scale modeling identifies energy consumption and solvent usage as key environmental hotspots. A scale-up framework is applied to provide valuable insights and guide the sustainable development of this emerging technology. Eco-design strategies and benchmarking indicate that direct recycling has the potential to reduce environmental impacts; however, advancements in process energy efficiency and material recovery rates are necessary to ensure its competitiveness with existing recycling methods and its ability to meet industry quality standards.