摘要:SummaryCritical materials such as rare earth underpin technologies needed for a decarbonized global economy. Recycling can mitigate the supply risks created by the increasing demand and net import dependence, and enable a circular economy for critical materials. In this study, we analyze the feasibility and life-cycle impacts of recovering critical materials from spent nickel metal hydride batteries from hybrid electric vehicles in the U.S., accounting for stocks, battery scrappage, and end-of-life reverse logistics, given uncertain future availability scenarios. Our results show that the total collection and recycling costs depend strongly on future battery availability, with marginal costs exceeding marginal revenues when the availability of spent batteries declines. We quantify the potential of recycling to reduce primary imports, as well as the accompanying climate change and resource impacts. We explore the underlying reverse logistics infrastructure required for battery recycling and evaluate strategies for reducing associated capital investment risk.Graphical abstractDisplay OmittedHighlights•We assess techno-economic and life-cycle impacts of large-scale HEV battery recycling•Recycling offsets primary critical material demand with lower environmental impacts•Flexible strategies mitigate investment risk from uncertain future battery availability•Marginal cost analysis can inform strategies for incentivizing collection and recyclingElectrochemical energy storage; Energy policy; Energy resources; Energy sustainability; Materials science;