Electrodialytic lithium extraction from secondary resources: Technical, environmental and economic assessment

In transportation, large-scale electrification, particularly through lithium-ion batteries, is expected to drive significant emissions reductions while simultaneously increasing global lithium demand. However, the limited availability of lithium, compounded by geopolitical constraints, poses risks to the energy transition, namely in the European Union. Adopting circular economy models offers a sustainable approach to increase resource recovery. The present research aims to assess the potential of the electrodialytic process for lithium recovery from wastewater generated during lithium-ion battery recycling and aluminium-lithium alloy dust processing, as well as related environmental and economic impacts. Bench-scale experiments were conducted using two-compartment electrodialytic reactors, operated at 50 mA, 100 mA and 200 mA with a cation-exchange membrane interposed. Tests were performed over 24 h, 48 h and 72 h. Lithium recovery reached 91.54 % from the aluminium-lithium alloy dust and 97.23 % from the wastewater of lithium-ion battery recycling. The cradle-to-gate life cycle assessment resulted in 0.26 kg of CO₂ eq/g Li global warming impacts for wastewater of lithium-ion battery recycling, and 46.40 kg of CO₂ eq/g Li for aluminium-lithium alloy dust. Material flow cost accounting showed lower recovery costs for wastewater (0.36 €/g Li versus 129.26 €/g Li). Energy consumption in the reactor is the primary hotspot, where optimizing energy and time efficiency could reduce environmental and economic impacts.