Selectively peeling of spent LiFePO4 cathode by destruction of crystal structure and binder matrix for efficient recycling of spent battery materials

Review of lithium-ion batteries' supply-chain in Europe: Material flow analysis and environmental assessment

European legislation stated that electric vehicles' sale must increase to 35% of circulating vehicles by 2030, and concern is associated to the batteries' supply chain. This review aims at analysing the impacts (about material flows and CO2 eq emissions) of Lithium-Ion Batteries' (LIBs) recycling at full-scale in Europe in 2030 on the European LIBs' supply-chain. Literature review provided the recycling technologies' (e.g., pyro- and hydrometallurgy) efficiencies, and an inventory of existing LIBs' production and recycling plants in Europe. European production plants exhibit production capacity adequate for the expected 2030 needs. The key critical issues associated to recycling regard pre-treatments and the high costs and environmental impacts of metallurgical processes. Then, according to different LIBs' composition and market shares in 2020, and assuming a 10-year battery lifetime, the Material Flow Analysis (MFA) of the metals embodied in End of Life (EoL) LIBs forecasted in Europe in 2030 was modelled, and the related CO2 eq emissions calculated. In 2030 the European LIBs' recycling structure is expected to receive 664 t of Al, 530 t of Co, 1308 t of Cu, 219 t of Fe, 175 t of Li, 287 t of Mn and 486 t of Ni. Of these, 99% Al, 86% Co, 96% Cu, 88% Mn and 98% Ni will be potentially recovered by pyrometallurgy, and 71% Al, 92% Co, 92% Fe, 96% Li, 88 % Mn and 90% Ni by hydrometallurgy. However, even if the recycling efficiencies of the technologies applied at full-scale are high, the treatment capacity of European recycling plants could supply as recycled metals only 2%-wt of the materials required for European LIBs' production in 2030 (specifically 278 t of Al, 468 t of Co, 531 t of Cu, 114 t of Fe, 95 t of Li, 250 t of Mn and 428 t of Ni). Nevertheless, including recycled metals in the production of new LIBs could cut up 28% of CO2 eq emissions, compared to the use of virgin raw materials, and support the European batteries' value chain.

Leaching kinetics of fluorine during the aluminum removal from spent Li-ion battery cathode materials

The high content of aluminum (Al) impurity in the recycled cathode powder seriously affects the extraction efficiency of Nickel, Cobalt, Manganese, and Lithium resources and the actual commercial value of recycled materials, so Al removal is crucially important to conform to the industrial standard of spent Li-ion battery cathode materials. In this work, we systematically investigated the leaching process and optimum conditions associated with Al removal from the cathode powder materials collected in a wet cathode-powder peeling and recycling production line of spent Li-ion batteries (LIBs). Moreover, we specifically studied the leaching of fluorine (F) synergistically happened along with the removal process of Al, which was not concerned about in other studies, but one of the key factors affecting pollution prevention in the recovery process. The mechanism of the whole process including the leaching of Al and F from the cathode powder was indicated by using NMR, FTIR, and XPS, and a defluoridation process was preliminarily investigated in this study. The leaching kinetics of Al could be successfully described by the shrinking core model, controlled by the diffusion process and the activation energy was 11.14 kJ/mol. While, the leaching of F was attributed to the dissolution of LiPF6 and decomposition of PVDF, and the kinetics associated was described by Avrami model. The interaction of Al and F is advantageous to realize the defluoridation to some degree. It is expected that our investigation will provide theoretical support for the large-scale recycling of spent LIBs.

Recovery of Li2CO3 from Spent LiFePO4 by Using a Novel Impurity Elimination Process

The large-scale implementations of lithium iron phosphate (LFP) batteries for energy storage systems have been gaining attention around the world due to their quality of high technological maturity and flexible configuration. Unfortunately, the exponential production of LFP batteries is accompanied by an annual accumulation of spent batteries and a premature consumption of the lithium resource. Recycling souring critical battery materials such as Li₂CO₃ is essential to reduce the supply chain risk and achieve net carbon neutrality goals. During the recovery of Li₂CO₃, impurity removal is the most crucial step in the hydrometallurgy process of spent LiFePO₄, which determines the purity of Li₂CO₃. By investigating and comparing the results of impurity elimination from the purified Li⁺-containing liquids with strong and weak alkalis under identical pH conditions, respectively, a strategy based on an alkali mixture has been proposed. The purified Li⁺-containing liquid was, thereafter, concentrated and sodium carbonate was added in order to precipitate Li₂CO₃. As a result, a high purity Li₂CO₃ (99.51%) of battery grade was obtained. LiFePO₄ prepared with the recovered Li₂CO₃ and FePO₄ as raw materials also displayed a comparative high capacity and stable cycle performance to the commercial product and further verified the electrochemical activity of the recovered materials.

A perspective on the recovery mechanisms of spent lithium iron phosphate cathode materials in different oxidation environments

Oxidative extraction has become an economically viable option for recycling lithium (Li) from spent lithium iron phosphate (LiFePO₄) batteries. In this study, the releases behaviour of Li from spent LiFePO₄ batteries under different oxidizing conditions was investigated with sodium hypochlorite (NaClO) as the solid oxidant. We revealed that, due to the intervention of graphitic carbon, the generated species of Li in mechanochemical oxidation (NaClO:LiFePO₄ at a molar ratio of 2:1, 5 min, and 600 rpm) was lithium carbonate (Li₂CO₃). The graphite layer provided a channel for the conversion of Li species released by mechanochemical oxidation. While in hydrometallurgical oxidation (NaClO:LiFePO₄ at a molar ratio of 2:1 and 12.5 min), the presence of hydrogen species led to the formation of lithium chloride (LiCl). Moreover, life cycle assessment (LCA) demonstrated that for recycling 1.0 kg of spent LiFePO₄ batteries, mechanochemical and hydrometallurgical oxidation could reduce carbon footprints by 2.81 kg CO₂ eq and 2.88 kg CO₂ eq, respectively. Our results indicate that the oxidative environment determines the release pathway of Li from the spent LiFePO₄ cathode material, thereby regulating the product forms of Li and environmental impacts. This study can provide key technical guidance for Li recycling from spent LiFePO₄ batteries.

Towards interactional management for power batteries of electric vehicles

With the ever-growing digitalization and mobility of electric transportation, lithium-ion batteries are facing performance and safety issues with the appearance of new materials and the advance of manufacturing techniques. This paper presents a systematic review of burgeoning multi-scale modelling and design for battery efficiency and safety management. The rise of cloud computing provides a tactical solution on how to efficiently achieve the interactional management and control of power batteries based on the battery system and traffic big data. The potential of selecting adaptive strategies in emerging digital management is covered systematically from principles and modelling, to machine learning. Specifically, multi-scale optimization is expounded in terms of materials, structures, manufacturing and grouping. The progress on modelling, state estimation and management methods is summarized and discussed in detail. Moreover, this review demonstrates the innovative progress of machine learning based data analysis in battery research so far, laying the foundation for future cloud and digital battery management to develop reliable onboard applications.