Life cycle assessment of recycling options for automotive Li-ion battery packs

Ramping up automotive lithium-ion battery (LIB) production volumes creates an imperative need for the establishment of end-of-life treatment chains for spent automotive traction battery packs. Life Cycle Assessment (LCA) is an essential tool in evaluating the environmental performance of such chains and options. This work synthesises publicly-available data to expand upon previously reported LCA studies for LIB recycling and holistically model end-of-life treatment chains for spent automotive traction battery packs with lithium nickel cobalt manganese oxide positive electrodes. The study provides an in-depth analysis of unit process contributions to the environmental benefits and burdens of battery recycling options and integrates these with the battery production impacts to estimate the net environmental benefit achieved by the introduction of recycling in the value chain. The attributional LCA model accounts for the whole recycling chain, from the point of end-of-life LIB collection to the provision of secondary materials for battery manufacturing. Pyrometallurgical processing of spent automotive traction battery cells is predicted to have a larger Global Warming Potential (GWP), due to its higher energy intensity, while hydrometallurgical processing is shown to be more environmentally beneficial, due to the additional recovery of lithium as hydroxide. The majority of the environmental benefits arise from the recovery of aluminium and copper fractions of battery packs, with important contributions also arising from the recovery of nickel and cobalt from the battery cells. Overall, the LCA model presented estimates a net benefit in 11 out of 13 environmental impact categories based on the ReCiPe characterisation method, as compared to battery production without recycling. An investigation of the effect of geographic specificity on the combined production and recycling indicates that it is as a key source of GWP impact variability and that the more climate burdening chains offer a significantly higher potential for GWP reductions through battery recycling. The sensitivity analysis carried out shows that impacts related to air quality are higher when recovering lower grade materials. This study provides a quantitative and replicable inventory model which highlights the significance of the environmental benefits achieved through the establishment of circular automotive battery value chains.