The nickel metal hydride (NiMH) battery technology has been designed for use in electric vehicles, solar-powered applications and power tools. These batteries contain the critical and strategic raw materials cobalt, nickel and several rare earth elements (REE). When designing a battery recycling process, there are several choices to be made regarding end-products and process chemicals. The aim of this study is to investigate and compare the environmental and economic sustainability of different recycling options for NiMH batteries by taking projected market developments into consideration and by applying life cycle assessment and life cycle costing methods. The comparative study is limited to recovery of the REEs. Two hydrometallurgical processes for recovery of the REEs from the anode material are compared with extraction of REEs from primary sources in China. The processes compared are a high-temperature sulfation roasting process and a process based on hydrochloric acid leaching followed by precipitation of REE oxalates. By comparing the different recycling approaches, the hydrochloric acid process performs best. However, the use of oxalic acid has a large impact on the overall sustainability footprint. For the sulfation roasting process, the energy, sodium hydroxide and sulphuric acid consumption contribute most to the total environmental footprint.

This article is part of the discussion meeting issue 'Sustainable metals: science and systems'.