Closing the Loop - Designing an Advanced Hydrometallurgical Lithium-Ion Battery Recycling Facility; An Approach to Sustainable Lithium Extraction in the Lithium Triangle

Modernization and global climate efforts have led us to an increased reliance on battery-based technologies: electric vehicles (EVs), wind and solar power, cell phones, and more all rely on lithium-ion batteries (LIBs) for energy storage. In both my technical and STS projects, I was curious about where the incredible element, lithium, comes from and where it goes. Quick internet searches into the topic showed me that the sourcing of metals that go into LIBs, like lithium and cobalt, is ethically questionable. Looking into end-of-life LIBs, I was surprised at how little progress there was in the way of recycling and recovering the precious metals within. I was inspired to approach the question of LIBs from two sides, technical and ethical. Thus, my STS thesis investigates the extraction of lithium from brines in the South American Lithium Triangle region, how doing so affects the local environment and human populations, and what values extraction engineers should implement to ameliorate the situation. In my technical project, my group and I designed a chemical plant to recycle end-of-life LIBs from EVs and regenerate their valuable metals for use in fresh battery manufacturing. Both projects aim to address sustainable supply chain practices, but from different ends of the chain; sourcing materials cannot destroy the planet and the cultures contained within. Once used, those materials cannot be left to languish in landfills, posing health and safety risks, when they can be given new life and circumvent the need to extract more raw materials. In either case, important steps must be taken to ensure a livable, fossil fuel-free future.
My technical project produced the design, as well as safety and economic analysis, of an industrial-scale LIB recycling facility. The facility would take in 100,000 metric tons of black mass (pre-processed and shredded LIB cathode material) per year and produce 19 tons of cobalt (II) hydroxide, 28 tons of manganese (II) carbonate, and 31 tons of nickel (II) hydroxide per year. We did so by leaching metals from the black mass into solution, removing the impurities, performing selective extractions, and then performing selective precipitations. While we were successful in designing a process to produce these valuable metal salts, the proposed plant would operate at more than $1 billion in losses per year, resulting in a no-go recommendation on the construction of the plant. However, this design is an emerging one, and we also made recommendations for future improvements which may significantly cut the costs of our plant, potentially making it profitable. My technical project was a valuable learning experience, allowing me to undergo all aspects of the design process, from initial conception to final decision. It was also valuable exercise in working as a team, as such a large design required constant communication and cooperation.
My STS research focused on the Lithium Triangle, the region where Argentina, Bolivia, and Chile’s borders meet. The Lithium Triangle is plentiful in lithium-rich salar lagoons, which are being exploited for their precious metals. I looked into how these operations affect the local environment and people, and found that the rights of indigenous communities and other locals were being trampled by mining corporations and the governments of the Lithium Triangle. One major issue is the lack of informed consent from communities for corporations to use the land. The corporations then proceed to divert millions of liters of fresh water per day to their extraction operations, depleting the region’s water resources. Through the lenses of Technological Momentum, Actor Network Theory, and Engineering Virtue ethics, I assessed how this system currently functions, how it will develop, and how we may continue to extract lithium more ethically. My recommendations include the mandated inclusion of local and indigenous populations in the mine licensing process, as well as the development of lithium recycling plants, like the one designed in my technical project, to drive down the demand of raw lithium.
Working on both of these projects side-by-side forced me to think about the social context of technology while working on my technical design, and to think about the role of technology as an actor in social networks while researching the issues in the Lithium Triangle. In my STS 4500 and 4600 classes, we discussed several case studies of technical crises arising from engineers not considering social and human factors in their designs; as a result, my group was careful in designing a system that passively addresses safety concerns. Working on my technical project also gave me important technical knowledge of the lithium extraction industry and its challenges, which informed the angle I took with my research and recommendations; I tried to remain realistic with what is technologically feasible while also trying to minimize the impacts on the local populations. Being able to apply course concepts from my design and ethics courses in each other’s projects allowed me to be a better engineer in both.
I would acknowledge some people who have helped me in the creation of this combined final product. Firstly, I would like to thank the members of my technical team: Gaurav Kapoor, Connor Dight, Benson Harlan, and Joseph Fink. These incredibly talented young engineers were the best team members I could have asked for. I would also like to acknowledge Professor Eric Anderson for his role as our technical advisor and the important industry insight he shared in his weekly meetings with us. I would also like to thank Professor William Davis for serving as my STS advisor; his writing and ethics advice (and infectious passion for ethical analysis) was instrumental in completing the STS portion of my capstone.

School of Engineering and Applied Science

Bachelor of Science in Chemical Engineering

Technical Advisor: Eric Anderson

STS Advisor: William Davis

Technical Team Members: Gaurav Kapoor, Connor Dight, Benson Harlan, Joseph Fink