Rapid leaching and recovery of valuable metals from spent Lithium Ion batteries (LIBs) via environmentally benign subcritical nickel-containing water over chlorinated polyvinyl chloride

Recovery of lithium and cobalt from lithium cobalt oxide and lithium nickel manganese cobalt oxide batteries using supercritical water

This study investigates the eco-friendly extraction of metal oxides from LCO and NMC batteries using supercritical water. Experiments were conducted at 450 °C with a feed rate of 5 mL min-1 and varying battery/PVC ratios (0.0, 2.0, and 3.0). The products were analyzed by X-ray diffractometry (XRD), atomic absorption spectrometry (FAAS) and gas chromatography-mass spectrometry (GC-MS). Results show the presence of cobalt chloride (CoCl2) and lithium (Li) in the liquid products, achieving 100% cobalt recovery under all conditions. The gaseous products obtained hydrogen with molar compositions up to 78.3% and 82.7% for LCO:PVC and NMC:PVC batteries, respectively, after 60 min of reaction. These findings highlight the potential of this methodology for lithium-ion battery recycling.

Improvement of Li and Mn bioleaching from spent lithium-ion batteries, using step-wise addition of biogenic sulfuric acid by Acidithiobacillus thiooxidans

Conventional spent lithium-ion battery (LIB) recycling procedures, which employ powerful acids and reducing agents, pose environmental risks. This work describes a unique and environmentally acceptable bioleaching method for Li and Mn recovery utilizing Acidithiobacillus thiooxidans, a sulfur-oxidizing bacteria that may produce sulfuric acid biologically. The novel feature of this strategy is the step-by-step addition of biogenic sulfuric acid, which differs significantly from conventional methods that use chemical reagents. We expected that gradually introducing biogenic sulfuric acid produced by A. thiooxidans would improve metal leaching at high pulp density. To investigate this, LIBs were disassembled and bioleached with or without a step-wise addition of the biogenic sulfuric acid approach. The impact on leaching efficiency, time, and ultimate product quality was assessed. Direct bioleaching yielded modest Li (43 %) and Mn (15 %) recoveries. However, bioleaching greatly increased metal recovery with the step-wise addition of biogenic acid. Li and Mn leaching efficiency were 93 % and 53 %, respectively, at a high pulp density of 60 g/L, while leaching time was reduced from 16 to 8 days. Following bioleaching, Mn(OH)2 and Li2CO3 were successfully precipitated from the leachate at more than 90 % purity. This study shows that gradually adding biogenic sulfuric acid can efficiently recover Li and Mn from waste LIBs. This approach has several environmental and economic advantages over conventional methods. The step-wise addition optimizes the leaching environment, increasing metal recovery rates while reducing the development of hazardous byproducts. This approach is environmentally friendly because it decreases greenhouse gas emissions and chemical waste. Economically, this technology offers potential cost savings through less chemical usage, shorter processing times, and lower energy needs, making it a more sustainable and cost-effective option for LIB recycling. This study shows that the step-wise addition of biogenic sulfuric acid may efficiently recover Li and Mn from wasted LIBs. This method provides a sustainable alternative to traditional procedures by limiting environmental impact while reducing process time and energy consumption.

The influence of chlorination additives on metal separation during the pyrometallurgical recovery of spent lithium-ion batteries

The difficulty of separating Li during pyrometallurgical smelting of spent lithium-ion batteries (LIBs) has limited the development of pyrometallurgical processes. Chlorination enables the conversion of Li from spent LIBs to the gas phase during the smelting process. In this paper, the effects of four solid chlorinating agents (KCl, NaCl, CaCl2 and MgCl2) on Li volatilization and metal (Co, Cu, Ni and Fe) recovery were investigated. The four solid chlorinating agents were systematically compared in terms of the direct chlorination capacities, indirect chlorination capacities, alloy physical losses and chemical losses in the slag. CaCl2 was better suited for use as a solid chlorinating agent to promote Li volatilization due to its excellent results in these indexes. The temperature required for the release of HCl from MgCl2, facilitated by CO2 and SiO2, was lower than 500 °C. The prematurely released HCl failed to participate in the chlorination reaction. This resulted in approximately 12 % less Li volatilization when MgCl2 was used as a chlorinating agent compared to when CaCl2 was used. In addition, the use of KCl as a chlorinating agent decreased the chemical dissolution loss of alloys in the slag. The performance of NaCl was mediocre. Finally, based on evaluations of the four indexes, recommendations for the selection and optimization of solid chlorinating agents were provided.

Assessment of an eco-efficient process for the optimization of metal recovery in lithium cobalt oxide and lithium nickel manganese cobalt oxide batteries

The expansion of technology motivates the increase of global demands for critical minerals. In this context, the exploration of secondary sources of these components is expanding. End-of-life batteries can be seen as potential sources of lithium, cobalt, nickel and manganese for electric vehicles or diverse applications in electronic equipments. This paper provides a comprehensive evaluation of the recovery of metals from waste batteries with diverse chemistry composition. Lithium cobalt oxide (LCO) and lithium nickel cobalt manganese oxide (NMC) batteries were co-treated with polyvinyl chloride (PVC) channels under supercritical water, varying reaction temperature (400-600 °C) and PVC/Battery composition (0-3 m/m) in a tubular continuous reactor. Results show high recovery rates for all metals, with up to 90% percentage recovery of lithium and cobalt in all cases. Temperature and feed composition were identified as determining factors for the recovery of lithium from LCO batteries. In the case of cobalt, temperature was identified as the most important factor that affects its recovery. The selected optimal conditions for cobalt recovery in the solid products of reactions were identified for batteries LCO and NMC: temperature of 600 °C and PVC/Battery ratio of 3.0 and temperature of 500 °C and PVC/Battery ratio of 1.5, respectively. Environmental impacts, primarily Global Warming Potential (GWP), were minimal, with 4.71·10-5 kg CO2 eq., indicating the benefits of the process as an eco-efficient and promising route for the recycling of valuable metals.

Ultrasound-assisted efficient and convenient method of extracting valuable metals (Ni, Co, and Cd) from waste Ni-Cd batteries using DL-malic acid

Recycling waste Ni-Cd batteries has received much attention recently because of the serious environmental pollution they cause and to avoid the dissipation of valuable metals. Despite significant research, it is still difficult to efficiently recycle valuable and hazardous metals from waste Ni-Cd batteries in an economical and environmentally friendly manner. This study employed a novel process utilizing ultrasound-assisted leaching to recover Ni, Cd, and Co from waste nickel-cadmium (Ni-Cd) batteries. Organic DL-malic acid served as the leaching agent and H2O2 was employed as an oxidizing agent. The effects of various factors on the recovery efficiency of Ni, Cd, and Co, such as leaching temperature, time, DL-malic acid concentration, pulp density, H2O2 concentration, and ultrasound frequency, were also examined. To predict the chemical compounds present before and after the recycling experiments, the solid residues from the metal extraction were analyzed using XRD, XPS, FE-SEM, and EDS element mapping. Concurrently, ICP-OES was utilized to determine the metal content in the leachate. Under optimized conditions of 90 °C, 90 min, 2M DL-malic acid, 160 mL/g pulp density, and 20% ultrasound frequency, over 83% of Ni, 94% of Cd, and 98% of Co were effectively leached from the waste Ni-Cd battery powder. The leaching kinetics of Ni, Cd, and Co followed the surface chemical reaction control model. The activation energies (Ea) for Ni, Cd, and Co leaching were 21.34, 20.47, and 18.38 kJ/mol, respectively. The findings suggest that ultrasound-assisted leaching is an efficient, cost-effective, environmentally friendly, and sustainable alternative for extracting precious and hazardous metals from waste Ni-Cd batteries. Additionally, it reduces industrial chemical usage and enhances waste management sustainability.

Designing Low Toxic Deep Eutectic Solvents for the Green Recycle of Lithium-Ion Batteries Cathodes

The Lithium-ion battery (LIB) is one of the main energy storage equipment. Its cathode material contains Li, Co, and other valuable metals. Therefore, recycling spent LIBs can reduce environmental pollution and resource waste, which is significant for sustainable development. However, traditional metallurgical methods are not environmentally friendly, with high cost and environmental toxicity. Recently, the concept of green chemistry gives rise to environmental and efficient recycling technology, which promotes the transition of recycling solvents from organic solvents to green solvents represented by deep eutectic solvents (DESs). DESs are considered as ideal alternative solvents in extraction processes, attracting great attention due to their low cost, low toxicity, good biodegradability, and high extraction capacity. It is very important to develop the DESs system for LIBs recycling for sustainable development of energy and green economic development of recycling technology. In this work, the applications and research progress of DESs in LIBs recovery are reviewed, and the physicochemical properties such as viscosity, toxicity and regulatory properties are summarized and discussed. In particular, the toxicity data of DESs are collected and analyzed. Finally, the guidance and prospects for future research are put forward, aiming to explore more suitable DESs for recycling valuable metals in batteries.

Hydrothermal treatment of polyvinyl chloride: Reactors, dechlorination chemistry, application, and challenges

Polyvinyl chloride (PVC) plastic wastes can bring a series of problems during pyrolysis or incineration such as the emission of dioxins, corrosion, slagging in the reactors, etc. Hydrothermal treatment of PVC plastics has been intensively studied as it can efficiently remove chlorine from PVC plastics under relatively mild reaction conditions (220-300 °C) to provide value-added products. Meanwhile, the research progress, knowledge gaps, and challenges in this field have not been well addressed yet. This paper gives a comprehensive review of hydrothermal dechlorination of PVC plastics regarding reactors, process variables and fundamentals, possible applications, and challenges. The main pathways of hydrothermal dechlorination of PVC plastics are elimination and -OH nucleophilic substitution. Catalytic hydrothermal and co-hydrothermal optimize the chemical reactions and transportation, boosting the dechlorination of PVC plastics. Hydrochar derived from PVC plastics, on the one hand, is coalified close to sub-bituminous and bituminous coal and can be used as low-chlorine solid fuel. On the other hand, it is also a porous material with aromatic structure and oxygen-containing functional groups, with good potential as adsorbent or energy storage materials. Further studies are expected to focus on waste liquid treatment, revealing the energy and economic balance, reducing the dechlorination temperature and pressure, expanding the application of products, etc. for promoting the implementation of the hydrothermal treatment of PVC plastic wastes.

Efficient separation and recovery of lithium through volatilization in the recycling process of spent lithium-ion batteries

Spent lithium-ion batteries (LIBs) comprise different kinds of valuable metals with recovery and reuse value. Aiming to address the difficulty of recycling lithium from spent LIBs through conventional pyrometallurgy, a new method of high-efficiency separation and recovery of lithium through volatilization is proposed. In this new method, spent LIBs as the raw material, copper slag as the only flux and CaCl₂ as an additive are utilized to recover lithium from spent LIBs. Under the optimal conditions, the volatilization rate of Li was 96.87%. During the smelting process, lithium is volatilized into the gas phase in the form of LiCl, where lithium can be recycled from the dust. In light of the experimental results, the addition of CaCl₂ contributes to the formation of LiCl. The kinetics study showed that the volatilization of LiCl was controlled by an interfacial chemical reaction, and the apparent activation energy was 42.57 kJ/mol. In addition, Li₂CO₃ could be obtained from lithium-containing dust using a precipitation process. This method achieves efficient separation of lithium during the reduction smelting process. The phase transformation and kinetics of the separation process were investigated, and reaction mechanism was revealed. Importantly, the novel process provides new ideas and perspectives for the separation of lithium from spent LIBs through a pyrometallurgical process.

Green products from herbal medicine wastes by subcritical water treatment

Herbal medicine wastes (HMWs) are byproducts of medicine factories, which are mainly landfilled for their environmental problems. Only bearing in mind the contamination and concerns caused by the COVID-19 pandemic and environmental emissions, the worth of herbal medicine wastes management and conversion to green products can be understood. In this work, subcritical water treatment was carried out batch-wise in a stainless tube reactor in the pressure range of 0.792-30.0 MPa, varying the temperature (127-327 °C) and time (1-60 min) of extraction. This resulted in new and green material sources, including organic acids, amino acids, and sugars. Amazingly, at very low extraction times (below 5 min) and high temperatures (above 277 °C), about 99% of HMWs were efficaciously converted to clean products by subcritical hydrothermal treatment. The results of hydrothermal extraction after 5 min indicated that at low temperatures (127-227 °C), the total organic carbon in the aqueous phase increased as the residual solid phase decreased, reaching a peak around 220 °C. Acetone soluble extracts or fat phase appeared above 227 °C and reached a maximum yield of 21% at 357 °C. Aspartic acid, threonine, and glycine were the primary amino acids; glycolic acid, formic acid, lactic acid, and acetic acid were obtained as the main organic acids, glucose, fructose, and cellobiose were substantial sugars produced from the aqueous phase after 5 min of hydrothermal subcritical hydrolysis extraction.

Recycling of NCM cathode material from spent lithium-ion batteries via polyvinyl chloride and chlorinated polyvinyl chloride in subcritical water: A comparative study

To date, numerous studies have explored recycling of lithium, nickel, cobalt, and manganese (NCM) from spent lithium-ion batteries (LIBs). Nevertheless, the leaching and efficient separation of the precious metals from NCM active cathode material via an environmentally benign and economical process is still challenging. Therefore, in this research, we present a novel and energy an efficient route through which to leach valuable metals, for example, lithium (Li), nickel (Ni), cobalt (Co), and manganese (Mn) from the NCM cathode material of the waste LIBs using water-containing waste chlorinated polyvinyl chloride (CPVC) or polyvinyl chloride (PVC) in a batch reactor. Parameters such as temperature, time, liquid-solid, and mass ratios on the extraction efficiencies of Li, Ni, Co, and Mn were carefully examined. The outcomes show that CPVC performed better than PVC for the extraction of valuable metals from NCM material, and this was attributed to its high Cl contents. The maximum extraction efficiencies of Li, Ni, Co, and Mn (99.15%, 98.10%, 99.30%, and 100%, respectively) were achieved under optimized reaction conditions: a temperature of 290 °C, reaction time of 1 h, a liquid-solid ratio 60:1 mL/g and solid to solid mass ratio of 1:3. The apparent activation energies (Ea) for Li, Ni, Co, and Mn were computed to be (24.42, 28.85, 29.67, and 28.79) kJ/mol. The results obtained in this work, indicated that it may contribute to efforts aiming to reduce industrial chemical consumption and increase sustainability in waste management technique.

Study of reaction characteristics and controlling mechanism of chlorinating conversion of cathode materials from spent lithium-ion batteries

Spent lithium-ion batteries (LIBs) recycling has attracted much attention because it is highly favorable to environment protection and sustainable development. Developing a cleaner method for metals extraction can greatly reduce risk of secondary pollution. Chlorinating technology has been proved as an efficient method for metals extraction instead of traditional hydrometallurgy. In this paper, cathode materials from spent LIBs could be rapidly converted into metal chlorides by NH₄Cl roasting at 623 K for 20 min. The results indicated nearly 100% metal leaching rates were achieved. Further, in-depth study is performed to obtain the mechanism function of chlorinating conversion based on roasting and TGA experiments. The apparent activation energy as 73.40 kJ/mol was firstly obtained, and then the reaction model of chlorination reaction was determined by model fitting and verifying. Herein, sub-reactions of chlorination reaction were figured out and their contributions were used to determinate reaction controlling mechanisms of chlorination reaction. The results indicated that nucleation reaction played a leading role in the initial stage (0.05 <α < 0.43) while phase boundary reaction took the control in next stage (0.43 <α < 0.95), which gave a good explanation to activation energy change. Finally, our findings provided inspirations for studying the controlling mechanism of gas-solid reaction.

Subcritical Water Extraction of Valuable Metals from Spent Lithium-Ion Batteries

The leaching of valuable metals (Co, Li, and Mn) from spent lithium-ion batteries (LIBs) was studied using subcritical water extraction (SWE). Two types of leaching agents, hydrochloric acid (HCl) and ascorbic acid, were used, and the effects of acid concentration and temperature were investigated. Leaching efficiency of metals increased with increasing acid concentration and temperature. Ascorbic acid performed better than HCl, which was attributed to ascorbic acid’s dual functions as an acidic leaching agent and a reducing agent that facilitates leaching reactions, while HCl mainly provides acidity. The chemical analysis of leaching residue by X-ray photoelectron spectroscopy (XPS) revealed that Co(III) oxide could be totally leached out in ascorbic acid but not in HCl. More than 95% of Co, Li, and Mn were leached out from spent LIBs’ cathode powder by SWE using 0.2 M of ascorbic acid within 30 min at 100 °C, initial pressure of 10 bar, and solid-to-liquid ratio of 10 g/L. The application of SWE with a mild concentration of ascorbic acid at 100 °C could be an alternative process for the recovery of valuable metal in spent LIBs. The process has the advantages of rapid reaction rate and energy efficiency that may benefit development of a circular economy.