Material Flow Analysis of Lithium-Ion Battery Recycling in Europe: Environmental and Economic Implications

This study aimed at a quantitative analysis of the material flows associated with End of Life (EoL) lithium-ion batteries’ (LIBs) materials in Europe. The European electric vehicles fleet in 2020 was taken as a case study, assuming a 10-year lifetime for the batteries and that the related EoL LIBs would be processed by existing recycling plants via pyrometallurgy, hydrometallurgy, or their combination in sequence. The economic implications (recycling operative costs compared to the revenues from the sales of the recycled metals) and the environmental performances (CO2 eq. emitted, energy demand and circularity performances) were assessed. Based on the gathered results, the existing European recycling capacity will overlook over 78% of the forecasted EoL LIBs. The treatment efficiencies of the full-scale recycling processes allow for the recovery of over 90% of copper, cobalt, nickel, and manganese, 87% of aluminum, and only 42% of lithium and 35% of iron entering the recycling facilities. In overall, LIBs recycling in 2030 will involve the emission of 3.7 Mt of CO2 eq. and an energy demand of 33.6 GWh. Hydrometallurgy presents the best economic and environmental trade-off compared to other recycling strategies. In conclusion, this study demonstrated that current European LIBs’ recycling infrastructure will be inadequate in the near future and the direction (i.e., hydrometallurgy) that its strengthening should pursue.