Sustainable Catalysis for Battery Recycling in Northvolt’s Supply Chain

Thesis Abstract

The rapid growth of lithium-ion battery production and secondary use has intensified the need for sustainable recycling pathways that minimize environmental impact while preserving material value within industrial supply chains. This study addresses the challenge of integrating efficient catalysis within Northvolt’s battery recycling supply chain to enhance the selective recovery of critical metals (Li, Co, Ni, Mn, and valuable transition metal oxides) from spent batteries, reduce energy intensity, and align with circular economy principles. The aim is to develop a catalysis-enabled recycling framework that improves metal recovery yield, purity, and process throughput while maintaining economic viability and safety. Specific objectives include (1) identifying catalytic routes that lower activation barriers for solvent-assisted hydrometallurgical and pyrochemical processes, (2) quantifying process performance under representative industrial conditions, (3) evaluating environmental and economic trade-offs through life cycle assessment and techno-economic analysis, (4) assessing integration with Northvolt’s logistics and waste streams, and (5) proposing a road map for scale-up and implementation. The methodological approach adopts a mixed-methods design combining experimental catalysis research with process modelling and stakeholder analysis. The research population comprises industrially sourced black mass from Northvolt’s post-consumer and post-industrial streams (n = 120 samples collected over 12 months) and pilot-scale reactor data (capable of handling 20–30 kg batches). A two-phase data collection strategy is employed. First, laboratory-scale experiments test a library of 12 solid-supported and homogeneous catalysts (including transition metal oxides, zeolite-templated materials, and organometallic complexes) to evaluate selectivity toward Li, Co, Ni, and Mn during acid-assisted leaching and solvent extraction steps, with reaction conditions iteratively optimised via Design of Experiments (DoE). Second, process-level data are gathered from Northvolt’s pilot facilities, including energy use, reagent consumption, throughput, and product purity metrics. Instrumentation includes inductively coupled plasma optical emission spectroscopy (ICP-OES) for metal quantification, X-ray diffraction (XRD) and scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX) for material characterisation, gas chromatography–mass spectrometry (GC-MS) for volatile by-products, and calorimetry for energy profiling. Data analysis employs response surface methodology (RSM) to model catalytic performance, regression analysis to relate catalyst characteristics to recovery yields, and multivariate statistical methods to identify significant factors. A life cycle assessment (LCA) following ISO 14040/14044 standards estimates environmental performance across cradle-to-gate boundaries, incorporating inventories of energy, water, reagents, and emissions. Techno-economic analysis (TEA) evaluates capex, opex, payback period, and levelised cost of metals (LCM). Sensitivity analyses probe robustness to market price fluctuations and supply variability. Theoretical underpinnings draw on catalytic reaction engineering and green chemistry principles, with theoretical framing provided by the Theory of Industrial Ecology and the Resource-Based View (RBV) to justify the integration of catalytic innovations with Northvolt’s unique capabilities. Where relevant, the study applies the Duhem–Quine thesis to acknowledge model uncertainty in process optimization and uses Bayesian updating to refine performance predictions as new pilot data emerge. Expected findings indicate that selected catalysts can lower leaching energy by 15–25% and increase selective recovery of Co and Ni by 8–12% relative to conventional hydrometallurgical routes, while reducing acid consumption and secondary waste formation. The integrated LCA is anticipated to show a net environmental improvement of 20–30% in global warming potential per kilogram of metal recovered, with a break-even capital expenditure achieved within 4–6 years under current metal price scenarios. The TEA is projected to reveal competitive LCM values aligned with industry benchmarks, contingent on catalyst lifetime and recycle rates. The study contributes to knowledge by demonstrating a scalable, catalysis-enabled approach to battery recycling that links material science with industrial ecology and operations management, providing a decision-support framework for policymakers and industry leaders. Recommendations include prioritising pilot-scale validation of the most selective catalysts, developing supplier partnerships for catalyst materials, implementing standardized process control analytics, and establishing performance monitoring dashboards that track energy intensity, selectivity, and emissions in real time to support continuous improvement and responsible scaling within Northvolt’s supply chain.