Evaluating economic and environmental viability of recycling lithium-ion battery for electric vehicles in the middle east: a case study in the UAE

The environmental impacts caused by the manufacturing of spent lithium-ion batteries (LIBs) and the supply risks of the valuable metals in electric vehicle (EV) batteries can be mitigated by recycling used LIBs. This study employed a Cradle-to-Gate life cycle assessment (LCA) and cost-benefit analysis, to evaluate the environmental and economic advantages of recycling and remanufacturing Nickel Manganese Cobalt (NMC) cells using hydrometallurgical and pyrometallurgical processes, compared to manufacturing with virgin materials. In the regional context, hydrometallurgy-based LIB remanufacturing has the potential to reduce energy consumption and greenhouse gas (GHG) emissions by 10.7%, accompanied by 11.3% cost savings, compared to virgin material manufacturing. However, despite its potential for GHG emission reduction, pyrometallurgy-based remanufacturing is economically unviable across all scenarios considered. The economics of LIB recycling are significantly influenced by spent LIB costs, requiring careful management of market trends and purchase expenses for feasibility. Challenges have arisen from the increasing volume of spent LIBs and production cost fluctuations. Various LIB chemical compositions yield nuanced outcomes, with NMC111 and NMC811 showing promise for economic and environmental aspects, respectively, while NMC532 and NMC111 demonstrate relative suitability for a cell remanufacturing. Preliminary analysis of Lithium Iron Phosphate (LFP) batteries, an emerging chemistry with growing adoption, highlights unique challenges underscoring the need for further research. This study marks the first economic and environmental evaluation of LIB recycling in the oil-rich Middle East, emphasizing the need for an assessment tailored to the UAE to inform regional policy development. This framework could be adapted for use in other Middle Eastern countries, aiding the formulation of effective regional policies and regulations.