Cradle-to-gate life cycle assessment of cobalt sulfate production derived from a nickel–copper–cobalt mine in China

In the booming electric vehicle market, the demand for refined cobalt is showing a blowout growth. China is the largest cobalt-refiner and cobalt-importer in the world. However, the life cycle inventory and potential environmental impact from cobalt refining in China have not been clearly illustrated. This paper builds a comprehensive inventory to support the data needs of downstream users of cobalt sulfate. A “cradle-to-gate” life cycle assessment was conducted to provide theoretical support to stakeholders. A life cycle assessment was performed based on ISO 14040 to evaluate the potential environmental impact and recognize the key processes. The system boundary of this study contains four stages of cobalt sulfate production: mining, beneficiation, primary extraction, and refining. Except for the experimental data used in the primary extraction stage, all relevant data are actual operating data. The normalization value was calculated based on the latest released global emission and extraction data. Normalization results show that the potential impacts of cobalt refining were mainly concentrated in the fossil depletion and freshwater ecotoxicity categories. The beneficiation stage and the refining stage account for 72% and 26% of the total normalization value, respectively. The beneficiation stage needs to consume a lot of chemicals and energy to increase the cobalt content, due to the low grade of cobalt ore in China. Compared with cobalt concentrate, the use of cobalt-containing waste (e.g., cobalt waste from EV batteries) can ease endpoint impact by up to 73%. With the application of the target electricity structure in 2050, the potential impact of China’s cobalt sulfate production on global warming, fossil depletion, and particulates formation can be reduced by 24%, 22%, and 26%, respectively. Findings indicate that the chemical inputs and electricity consumption are primary sources of potential environmental impact in China’s cobalt sulfate production. Promoting the development of urban mines can reduce excessive consumption of chemicals and energy in the beneficiation stage. The environmental benefits of transforming the electricity structure and using more renewable energy to reduce dependence on coal-based power in the cobalt refining industry were revealed.