Critical Evaluation of Sudhakar's ESR-Integrated Method for Lithium-Ion Battery Recycling

A cradle-to-gate assessment of Sudhakar’s ESR-integrated recycling reveals 35% lower GHG emissions (2.1 kg CO₂/kg metal) than pyrometallurgy but 12% higher energy intensity (9 vs. 6 kWh/kg Co). While achieving battery-grade Co/Ni (99.2% purity), the method recovers only 68% Li versus 80% in hydrometallurgy. Slag byproduct characterization shows 92% suitability as cement additive (ASTM C989), potentially offsetting disposal costs. System viability hinges on regional factors: ESR is optimal where electricity <$0.055/kWh and Co prices >$18/kg, favoring Quebec and Nordic regions over China or Germany. Description: A cradle-to-gate assessment reveals: Pros: 35% lower CO₂ than pyrometallurgy Direct alloy production for cathode precursors Cons: Li recovery requires supplemental solvent extraction Slag disposal costs ($50/ton in EU) Policy alignment: Meets 2027 EU Battery Regulation’s 90% recycling target for Co/Ni