• lithium-ion battery
• performance prediction
• process design
• recycling process

The upcoming era of transport electrification leaded by PHEVs and BEVs will represent a great opportunity in challenging climate change without radically giving up on our current behaviors, but the foreseen exponential spread of EVs will have to be supported by the development of appropriate facilities able to handle spent EVs batteries, otherwise ecological benefits coming from the switch to electric mobility will be worthless. The core technology at the base of EVs is the lithium-ion battery (LIB), specifically that one based on NMC chemistry. In this thesis the first target is pointing out a feasible and efficient recycling process within industrially developed and emerging battery recovery processes even changing some steps. Then the chosen recycling route is used as base for the design of a completely new process plant with the aim of obtaining block diagrams, quantified process flow diagrams, process and instrumentations diagrams and detailed equipment design. A LIB including a positive electrode made by recycled material, will have worse electrochemical performances than a reference LIB made by virgin materials. Thus, a recycled LIBs performance assessment is carried out in order to predict the likely performances of a recycled LIB and to analyze feasible compensation measures, which allow to achieve the same performances of the reference LIB.