Enhancing lithium recovery from spent lithium-ion batteries: Techno-economic analysis comparison with and without extractant recovery process

The recovery of Lithium (Li) from Lithium-ion batteries (LiBs) via solvent extraction faces challenges due to the significant dissolution of extractants into the aqueous phase, leading to considerable economic losses and environmental concerns. To address this issue and support a sustainable LiBs industry, this study proposes a breakthrough for recovering and recycling extractants during the Li extraction process. The process includes three key stages: Extraction, Stripping, and Extractant Recovery. Experimental results demonstrated that approximately 89 % of the extractant loss can be recovered to the organic phase at pH 1. Based on experimental data, a comprehensive mass balance and techno-economic analysis were conducted for the entire process. Using the Lithium hydroxide monohydrate (LiOH·H₂O) production process as a case study, economic indices were compared for processes with and without extractant recovery. At a processing capacity of 0.165 t/h of Li, the implementation of extractant recovery resulted in a 14.5 % Return on Investment (ROI) and 6.03 years Payback Period (PBP), compared to an ROI of 12.3 % and a PBP of 7.03 years for the conventional process without recovery. This approach not only significantly reduces economic losses but also enhances the sustainability and scalability of Li recycling operations, offering a viable pathway for the commercialization of advanced Li extraction technologies.