The study establishes technical, economic and life-cycle baselines for mechanically producing black mass, the electrode-powder concentrate used in downstream metal recovery. The same pilot flowsheet achieved 93.28 wt% separation efficiency for electric-vehicle modules and 75.77 wt% for mobile-phone cells. Using measured pilot data, the model estimated loaded costs of US$0.31–0.73/kg and net profits of US$4.39–5.53/kg under specified feedstock-price assumptions. These are modelled economics, not realised commercial-plant accounts.
Key findings
- Black-mass separation efficiency was 93.28 wt% for electric-vehicle modules and 75.77 wt% for mobile-phone cells, showing that feedstock architecture materially affects the same flowsheet.
- Pilot-data-based loaded costs were US$0.31–0.73/kg and baseline net profits US$4.39–5.53/kg under the assumed feedstock purchase prices.
- Market simulation put the probability of unprofitability below 0.2%, but this is conditional on the model's ranges and distributions, not a guarantee of commercial returns.
- Global-warming potential was 0.210–0.241 kg CO2-equivalent per kilogram of input, with grid electricity contributing most of the burden.
- A low-carbon electricity scenario reduced global-warming potential by 62.8%, making grid decarbonisation a major lever alongside equipment performance.
Why this matters globally
Black mass links end-of-life battery collection with recovery of lithium, nickel, cobalt and other materials. This study offers a joint cost-and-carbon benchmark for comparing recycling routes and shows how battery design and electricity mix alter outcomes. Circular-economy claims still require downstream metal yield and quality, logistics, safety and full-scale plant evidence.
Thai researcher contribution
Suranaree University of Technology researchers, working with the University of Leicester, integrated metallurgical engineering, pilot mechanical separation, process economics and life-cycle assessment. The collaboration places a Thai institution in the development of internationally useful baselines for battery-recycling infrastructure supporting electric mobility.
Limitations to consider
The process evidence is pilot scale and covers only two feedstock types, not the range of chemistries, ageing, contamination and pack designs. Cost and profit depend on purchase prices, black-mass value, utilisation and market assumptions; LCA depends on system boundaries and electricity mix. Producing concentrate does not establish downstream metal recovery or battery-grade quality, while safety, logistics, permitting and scale-up remain unverified commercially.