Environmental Impacts of Recovering Li, Co, and Mn from Li-Ion Batteries via Hydrometallurgical Sulfuric Acid Processing

Abstract The global demand for metals has experienced a critical increase in recent decades, and this trend is anticipated to persist in the coming years. Notably, the electric and electronic devices (EEE) sector and the electric vehicle industry are emerging as significant contributors to this heightened demand. Within these domains, the key player in terms of metal consumption is the battery, with Lithium-ion (Li-ion) batteries being the predominant choice due to their efficiency. Several methods have been investigated to recover metals from Li-ion batteries, focusing on the recovery without assessing the impacts generated. To address this gap, an experimental analysis focused on the recovery of crucial metals found in smartphones and laptop batteries, including lithium (Li), cobalt (Co), and manganese (Mn) was conducted. Then, the life cycle assessment was undertaken to calculate the environmental impacts of the hydrometallurgical route by using sulfuric acid and to analyze the ecological footprint associated with the recycling process. The acquired experimental data served as a basis for simulating the recycling process using specialized software, HSC Chemistry. This simulation facilitated the process's scaling up and enabled optimization and precise calculation of reagents and water usage during recycling. Thus, this study not only explores the difficulties of recycling processes but also the impacts associated with them, offering valuable insights into the ongoing discussions around responsible and sustainable practices in response to the growing global demand for metals. Graphical Abstract