Reducing the environmental footprint of the battery sector: assessment of a new recycling process from a techno-economic and life cycle perspective

• A novel direct recycling method recovering graphite from batteries is examined. • Low GWP and MSP of 4.06 kg CO 2-eq and 9.87 EUR per kg graphite are found. • Energy consumption drives the environmental impacts. • Considerable revenues arise from by-products produced. • Direct recycling can help reduce dependence on virgin critical materials. The rising demand for lithium-ion batteries increases the need for sustainable end-of-life pathways that recover critical materials with low environmental burden. This study assesses a novel direct recycling process for recovering battery-grade graphite from spent NCA lithium-ion cells using primary data from a continuous pilot-scale plant. A combined techno-economic and life cycle assessment is performed, supported by sensitivity analysis, scenario analysis, and Monte Carlo simulation. The process delivers low environmental impacts, with a global warming value of 4.06 kg CO 2 -eq per kg of graphite and achieves economic viability with a positive net present value at year ten. The minimum selling price is 9.87 €/kg when co-product revenues are included. The findings indicate that direct recycling provides an efficient and environmentally preferable route for high-quality graphite recovery. The technology can enhance circularity in battery value chains and reduce reliance on virgin resources in Europe and the United States.