Global Warming Potential of a New Waterjet-Based Recycling Process for Cathode Materials of Lithium-Ion Batteries

Abstract

Due to the increasing demand for battery electric vehicles (BEVs), the need for vehicle battery raw materials is increasing. The traction battery (TB) of an electric vehicle, usually a lithium-ion battery (LIB), represents the largest share of a BEV’s CO2 footprint. To reduce this carbon footprint sustainably and to keep the raw materials within a closed loop economy, suitable and efficient recycling processes are essential. In this life cycle assessment (LCA), the ecological performance of a waterjet-based direct recycling process with minimal use of resources and energy is evaluated; only the recycling process is considered, waste treatment and credits for by-products are not part of the analysis. Primary data from a performing recycling company were mainly used for the modelling. The study concludes that the recycling of 1 kg of TB is associated with a global warming potential (GWP) of 158 g CO2 equivalents (CO2e). Mechanical removal using a water jet was identified as the main driver of the recycling process, followed by an air purification system. Compared to conventional hydro- or pyrometallurgical processes, this waterjet-based recycling process could be attributed an 8 to 26 times lower GWP. With 10% and 20% reuse of recyclate in new cells, the GWP of TBs could be reduced by 4% and 8%, respectively. It has been shown that this recycling approach can be classified as environmentally friendly.

A toolbox for improved recycling of critical metals and materials in low-carbon technologies

“…The high voltage pulse crushing technique was reported to recover >90% of Ag and Cu from Si solar panels. 56 Other techniques like water jet pulverisation 57,58 or laser cutting 59 were reported to “cut” selectively the metal-containing parts from the end-of-life material. However, most of these techniques remain expensive and, so far, can hardly compete with the high-capacity industrial machines available for size-reduction.…”

Roadmap for a sustainable circular economy in lithium-ion and future battery technologies

“…Instead of traditional shredding and milling processes, automated lasers or automated high-pressure jets of water (with optional abrasives) have been suggested as methods for opening cells [105]. Water jets would have the advantage of acting as a heat sink during the cutting process and have also been suggested for separating active material from current collectors [106]. Electrohydraulic fragmentation uses shockwaves from a spark discharge under water to break composite materials apart at their interfaces [107].…”

A phenomenological and quantitative view on the degradation of positive electrodes from spent lithium-ion batteries in humid atmosphere

“…In this process, the coating consisting of NMC, conductive carbon black and binder is gently removed from the aluminum carrier foil using a high-pressure water jet, to which various additives can optionally be mixed. This comparatively simple technology makes this process the most efficient and environmentally friendly compared to the other known industrial recycling processes 13 . A particular advantage of this process is the high material quality of the recovered NMC recyclate, so that it can be used directly as an admixture to new cathode material for the production of new positive electrodes 14 .…”