Sustainable Recycling of Lithium-Ion Battery Cathodes: Life Cycle Assessment, Technologies, and Economic Insights

Rapid growth of electric vehicles has increased demand for lithium-ion batteries (LIBs), raising concerns regarding their end-of-life management. This study comprehensively evaluates the closed-loop recycling of cathode materials from spent LIBs by integrating life cycle assessment (LCA), technoeconomic analysis, and technological comparison. Typical approaches—including pyrometallurgy, hydrometallurgy, and other processes such as organic acid leaching and in situ reduction roasting—are systematically reviewed. While pyrometallurgy offers scalability, it is hindered by high energy consumption and excessive greenhouse gas emissions. Hydrometallurgy achieves higher metal recovery rates with better environmental performance but requires complex chemical and wastewater management. Emerging methods and regeneration techniques such as co-precipitation and sol–gel synthesis demonstrate potential for high-purity material recovery and circular manufacturing. LCA results confirm that recycling significantly reduces GHG emissions, especially for high-nickel cathode chemistry. However, the environmental benefits are affected by upstream factors such as collection, disassembly, and logistics. Technoeconomic simulations show that profitability is strongly influenced by battery composition, regional cost structures, and collection rates. The study highlights the necessity of harmonized LCA boundaries, process optimization, and supportive policy frameworks to scale environmentally and economically sustainable LIB recycling, ensuring long-term supply security for critical battery materials.