Feasibility of Upcycling Spent Lithium-ion Battery to Carbon Dioxide Capture Adsorbent

Author

• Chimezie Frank Onwudinjo, Bucknell UniversityFollow

Date of Thesis

Summer 2026

Description

This study investigates the feasibility of repurposing spent lithium-ion battery (SLIB) to lithium orthosilicate (Li₄SiO₄), a high temperature carbon dioxide sorbent. Two synthesis pathways including conventional acid-leaching method (Scenario 1) and a pyrolysis-based route (Scenario 2) were explored. Additionally, techno-economic analysis (TEA) and lifecycle assessment (LCA) of the two processes were also performed. Different analytical characterization techniques were performed to understand the material properties of Li₄SiO₄ including surface area, crystallinity, morphology and thermal stability. CO₂ capture performance of the synthesized Li₄SiO₄ was tested in a thermogravimetric analyzer (TGA) using dynamic, isothermal and cyclic methods. Dynamic test shows the adsorption-desorption peak temperatures of 602^oC and 500^oC for the leaching-based and pyrolysis-based sorbents respectively. The material produced from Scenario 1 had an isothermal CO₂ capture capacity ranging from 0.10 – 0.27 g CO₂/ g of sorbent. On the contrary, Scenario 2 had a higher adsorption capacity ranging from 0.18 – 0.33 g CO₂/ g of sorbent. Over 10 cycles, cyclic CO₂ capture was performed for about 1500 min using the leaching-based and pyrolysis-based sorbents, showing that an adsorption potential of 99.5% was consistently maintained by scenario 1’s sorbent, while scenario 2 experienced a drastic decline in adsorption rate with 88% as its lowest. The TEA shows that Scenario 1 yields a minimum selling price (MSP) of US$ 3.49/kg and a payback period (PBP) of ≈ 2 years and 10 months, while Scenario 2 results in an MSP of US$ 3.65/kg and a PBP of ≈ 3 years. Both pathways are economically feasible. However, Scenario 1 demonstrates a lower production cost and higher net present value under base-case assumptions.

Keywords

Spent lithium-ion batteries, Battery Discharge, Leaching, Pyrolysis, Lithium orthosilicate, Carbon dioxide sorbent, Techno-Economic Analysis, Life Cycle Assessment.

Access Type

Masters Thesis

Degree Type

Master of Science in Chemical Engineering

Major

Chemical Engineering

First Advisor

Dr. Jude A. Okolie

Recommended Citation

Onwudinjo, Chimezie Frank, "Feasibility of Upcycling Spent Lithium-ion Battery to Carbon Dioxide Capture Adsorbent" (2026). Master’s Theses. 316.
https://digitalcommons.bucknell.edu/masters_theses/316