Scalable Upcycling of Spent Lithium‐Ion Battery Anodic Graphite to Electronic‐Grade Graphene

ABSTRACT Recycling processes for lithium‐ion batteries (LIBs) are imperative to support the sustainable growth of global energy storage systems. This study introduces a scalable method for the upcycling of spent graphite anodes from LIBs to produce electronic‐grade graphene nanoplatelets. In addition to comprehensive materials characterization, the electronic quality of the upcycled graphene is demonstrated by formulating it into a screen printing ink that achieves high‐resolution patterning and thin‐film electrical conductivity exceeding 10 4 S m −1 . This screen printing ink is also used to print planar micro‐supercapacitors with exceptional areal capacitance (1.78 mF cm −2 ), areal energy density (0.247 µWh cm −2 ), and cycling stability (> 10 000 cycles). Life cycle assessment (LCA) and techno‐economic analysis (TEA) highlight the environmental benefits and cost reductions attainable through upcycling of graphite from LIBs. By capturing economic value from spent LIBs, this work fosters a sustainable battery supply chain and provides an abundant and geographically distributed raw material for electronic‐grade graphene.