Abstract

Electric vehicles (EVs) play a pivotal role in decarbonizing transportation by providing a cleaner alternative to fossil fuels. However, realizing their full sustainability potential requires the entire battery supply chain to be environmentally friendly. Lithium-ion batteries have enabled the rapid adoption of EVs, yet life cycle assessments (LCAs) show that their highest environmental impact stems from upstream raw material production. This thesis addresses these challenges by examining electrode components through three perspectives: lithium production, nickel extraction, and binder sustainability. First, we conducted an LCA of LiOH·H₂O production in Québec. The results indicate a short-term climate change impact of 4.395 t CO₂-eq per ton of LiOH·H₂O and a water scarcity footprint of 9,422.31 m³ world eq after using sodium sulfate co-products credits. Natural gas combustion in the calciner was identified as the primary contributor to emissions, highlighting electrification of the process as a promising mitigation pathway given Québec’s hydroelectric energy mix. Next, the thesis explores nickel recovery through the sulfation-roasting process using a dual-salt additive system of Na₂SO₄ and K₂SO₄. As Na₂SO₄ is a by-product from LiOH·H₂O production, its usage for nickel recovery promotes a circular economy within critical mineral supply chains. Under optimized conditions (650°C, 2.5 h, 4 g Na₂SO₄, 1.25 g K₂SO₄), the process achieved 79% Ni extraction and 95% Fe recovery, with the recovered iron oxide suitable as a precursor for LiFePO₄ cathode materials. Finally, the thesis evaluates sustainable aqueous binders as replacements for PVDF/NMP systems, addressing toxicity and solvent-related impacts.