The global lithium supply is projected to stagnate amid rapidly growing demand, driven primarily by electric vehicle (EV) adoption and global net-zero emissions goals. By 2040, planned mining operations are expected to fall short of projected demand, exacerbated by geopolitical tensions and trade barriers. To mitigate supply chain risks and support the clean energy transition, the development of sustainable refining and recycling infrastructure for critical battery materials (e.g. lithium, cobalt) is imperative. Current U.S. battery recycling facilities process approximately 10,000 tonnes/year of material per facility, with aspirations to reach 100,000 tonnes/year, yet many rely on energy-intensive pyrometallurgical methods. This design project serves to evaluate the technical and economic feasibility of a hydrometallurgical black mass recycling process at the 100,000-tonne/year scale, where ”black mass” is a fine powder derived from shredded EV batteries. Our process offers three key advantages: (1) lower emissions and higher selective recovery of individual metals than pyrometallurgy, (2) scalable capacity surpassing existing recycling infrastructure, and (3) reduced environmental and ethical concerns compared to traditional mining. Economic analysis reveals various challenges. Under the base case assumptions (25-year plant lifetime, NMC carbonate mixture at $9,341/tonne, lithium carbonate at $9, 758/tonne), the process produces a negative NPV at -$683 MM. Profitability (NPV $125MM) is achievable only at the highest prices of NMC -$19,650/tonne. Despite marginal economics, the process achieves 95% separation efficiency, competitive with pyrometallurgical benchmarks. This work establishes a critical baseline for large-scale recycling and highlights its potential necessity if global supply shortages occur.