A systematic exploration of milling parameters was performed for improving reduction of cobalt from LCO cathode by aluminium, followed by magnetic extraction. Lithium-ion batteries (LIBs) stand as the dominant power source for electric vehicles owing to their mature technology and exceptional performance. Consequently, metallic components of LIB cathode materials (Ni, Co, Li, and Mn) are assuming strategic significance. The imperative recycling of these metals has necessitated the development of novel technologies that can curtail secondary pollution arising from prevailing hydrometallurgical procedures, including issues such as wastewater generation and excessive energy and chemical consumption. In this study, we present an optimised mechanochemical process tailored for the magnetic recovery of cobalt from LiCoO 2 , which is a crucial component of LIBs. Our methodology involves the initial reduction of cobalt, facilitated by aluminium, followed by a selective extraction process that leverages the magnetic properties of the obtained species. A systematic exploration of milling parameters was undertaken to comprehensively understand their influence on chemical reactions and to improve reduction efficiency. This research represents a significant stride towards fostering sustainable practices in the realm of LIB cathode material recycling, addressing critical concerns related to resource management and environmental impact.