Pathway decisions for reuse and recycling of retired lithium-ion batteries considering economic and environmental functions

Reuse and recycling of retired electric vehicle (EV) batteries offer a sustainable waste management approach but face decision-making challenges. Based on the process-based life cycle assessment method, we present a strategy to optimize pathways of retired battery treatments economically and environmentally. The strategy is applied to various reuse scenarios with capacity configurations, including energy storage systems, communication base stations, and low-speed vehicles. Hydrometallurgical, pyrometallurgical, and direct recycling considering battery residual values are evaluated at the end-of-life stage. For the optimized pathway, lithium iron phosphate (LFP) batteries improve profits by 58% and reduce emissions by 18% compared to hydrometallurgical recycling without reuse. Lithium nickel manganese cobalt oxide (NMC) batteries boost profit by 19% and reduce emissions by 18%. Despite NMC batteries exhibiting higher immediate recycling returns, LFP batteries provide superior long-term benefits through reuse before recycling. Our strategy features an accessible evaluation framework for pinpointing optimal pathways of retired EV batteries.