A novel integrating approach to assess the role of LiFePO4 battery recycling in the automotive industries in the Greater Bay Area of China

Amidst the swift progression and extensive use of electric vehicles, demands on lithium iron phosphate (LiFePO4) batteries have surged, leading to an imminent scarcity of raw materials for battery manufacturing. This reality heightens the needs for effective battery recycling. This study outlines an integrated evaluation approach of combining laboratory-scale pilot experiment, Monte Carlo Simulations, and Life Cycle Assessment (LCA). An optimized recycling process for LiFePO4 batteries was developed, aiming to salvage and retrieve valuable elements. The process involves lithium's selective leaching followed by subsequent lithium (Li) and iron (Fe) recovery, achieving efficient recovery rates for both Li and Fe. A novel evaluation, integrating economic and environmental aspects, was conducted by employing a direct costs/revenues approach, with the inclusion of stochastic uncertainties determined via Monte Carlo Simulation. Two scenarios are applied to the electric vehicles data of Guangzhou in 2022. The recycling strategy of spent lithium-ion batteries (LIBs) within the Greater Bay Area of China (Scenario A) could potentially save 373.2 million US$, and reduce carbon dioxide emissions by 96,850 tons, compared to manufacturing batteries from mined raw materials and long-distance transportation (Scenario B). This demonstrates the importance of localized, efficient industrial automotive chain within the Greater Bay Area, which besides being cost-effective, offers profound environmental benefits. Other important factors for the result are the efficiency of the developed hydrometallurgical process, the price of the sellable material, and the transport distance. Scenario modelling results from the developed integrating evaluation clearly reveal the significant potential of battery recycling, and the innovative integrating approach has the potential for broader applicability beyond the specific context of our study.