Onwudinjo, Frank, Chemical Engineering, Bucknell University, 216 Market St (Apt C), United States of America, Pennsylvania, 17837, cfponwudinjo@gmail.com; Okolie, Jude, A, Chemical Engineering, Bucknell University, 1 Dent drive, Lewisburg, Pennsylvania, 17837, jude.okolie@bucknell.edu.
This study highlights the techno-economic assessment (TEA) and spatial analysis integrated with the life cycle assessment of upcycling spent lithium-ion batteries (SLIBs) into a CO₂ adsorbent. The analysis integrates both economic feasibility and geographic considerations to evaluate the potential of this sustainable approach. Based on critical suitability geospatial criteria for identifying optimal siting locations for SLIB upcycling, factors such as population density, digital elevation model, CO₂ sources, land cover, recycling facilities, and environmentally sensitive areas were examined using high-resolution geographic information system (GIS) data from the region. The suitability maps show that high-potential zones around central & western Pennsylvania, Southern portion of New Jersey and central & western Maryland. Overall, CWPA and northern western Virginia are the most viable areas for location of SLIB recycling facilities, based on feedstock availability, land availability, optimal infrastructure connectivity, and minimal conflict with environmental or urban constraints. Two scenarios for repurposing SLIB to Li4SiO4, traditional method and the proposed techniques, were evaluated through a holistic TEA to determine its economic feasibility and cost-effectiveness of siting a SLIB upcycling facility in the most suitable location within the region. Scenario 1 includes the conventional leaching method while scenario 2 follows high temperature pyrolysis. Comparative cost analysis shows that the minimum selling price (MSP) of Li-based sorbent for scenario 1 is US$1.97/kg, while scenario 2 is US$ 2.02/kg. The payback period (PBP) for scenario 1 and scenario 2 is 10 and 11 months respectively. The results indicate that scenario-1 is more economically profitable for SLIB upcycling within the mid-Atlantic region. Scenario 1 (leaching) is also environmentally preferable, showing a lower global warming potential of ~2.5 kg CO₂-eq/kg due to its lower energy requirement and despite its higher acidification and chemical-related burdens. Our findings would serve as a helpful tool for upscaling and commercialization of this sustainable precious metals’ recovery process, enabling investors to determine the worth-venturing technique to explore for SLB upcycling and regional decarbonization planning.
Lithium Orthosilicate, Battery, Techno-economic, GIS