Selective extraction and separation of metal values from leach liquor of mixed spent Li-ion batteries

Comprehensive review and comparison on pretreatment of spent lithium-ion battery

Pretreatment, the initial step in recycling spent lithium-ion batteries (LIBs), efficiently separates cathode and anode materials to facilitate key element recovery. Despite brief introductions in existing research, a comprehensive evaluation and comparison of processing methods is lacking. This study reviews 346 references on LIBs recycling, analyzing pretreatment stages, treatment conditions, and method effects. Our analysis highlights insufficient attention to discharge voltage safety and environmental impact. Mechanical disassembly, while suitable for industrial production, overlooks electrolyte recovery and complicates LIBs separation. High temperature pyrolysis flotation offers efficient separation of mixed electrode materials, enhancing mineral recovery. We propose four primary pretreatment processes: discharge, electrolyte recovery, crushing and separation, and electrode material recovery, offering simplified, efficient, green, low-cost, and high-purity raw materials for subsequent recovery processes.

Low-carbon footprint diluents in solvent extraction for lithium-ion battery recycling

This study investigated the influence of the diluent on the extraction properties of three extractants towards cobalt(ii), nickel(ii), manganese(ii), copper(ii), and lithium(i), i.e. Cyanex® 272 (bis-(2,4,4-trimethylpentyl)phosphinic acid), DEHPA (bis-(2-ethyl hexyl)phosphoric acid), and Acorga® M5640 (alkylsalicylaldehyde oxime). The diluents used in the formulation of the extraction solvents are (i) low-odour aliphatic kerosene produced from the petroleum industry (ELIXORE 180, ELIXORE 230, ELIXORE 205 and ISANE IP 175) and (ii) bio-sourced aliphatic diluents (DEV 2138, DEV 2139, DEV 1763, DEV 2160, DEV 2161 and DEV 2063). No influence of the diluent and no co-extraction of lithium(i), nickel(ii), cobalt(ii), manganese(ii) and aluminum were observed during copper(ii) extraction by Acorga M5640. The nature of the diluent influenced more significantly the extraction properties of manganese(ii) by DEHPA as well as cobalt(ii) and nickel(ii) by Cyanex® 272. Life cycle assessment of the diluents shows that the carbon footprints of the investigated diluents followed the following order: (ELIXORE 180, ELIXORE 230, ELIXORE 205) from petroleum industry > kerosene from petroleum industry > diluent produced from tall oil (DEV 2063) > diluents produced from recycled plastic (DEV 2160, DEV 2161) > diluents produced from used cooking oil (DEV 2138, DEV 2139). By taking into account the physicochemical properties of these diluents (viscosity, flashpoint, aromatic content), the extraction properties of Acorga® M5640, DEHPA, Cyanex® 272 in these diluents and the CO2 footprint of the diluents, this study showed DEV2063 and DEV2139 were the best diluents. A low-carbon footprint solvent extraction flowsheet using these diluents was proposed to extract selectively cobalt, nickel, manganese, lithium and copper from NMC black mass of spent lithium-ion batteries.

Optimized purification methods for metallic contaminant removal from directly recycled Li-ion battery cathodes

Metallic contaminants pose a significant challenge to the viability of directly recycling Li-ion batteries. To date, few strategies exist to selectively remove metallic impurities from mixtures of shredded end-of-life material (black mass; BM) without concurrently damaging the structure and electrochemical performance of the target active material. We herein present tailored methods to selectively ionize two major contaminants-Al and Cu-while retaining a representative cathode (LiNi_0.33Mn_0.33Co_0.33O₂; NMC-111) intact. This BM purification process is conducted at moderate temperatures in a KOH-based solution matrix. We rationally evaluate approaches to increase both the kinetic corrosion rate and the thermodynamic solubility of Al⁰ and Cu⁰, and evaluate the impact of these treatment conditions on the structure, chemistry, and electrochemical performance of NMC. Specifically, we explore the impacts of chloride-based salts, a strong chelating agent, elevated temperature, and sonication on the rate and extent of contaminant corrosion, while concurrently evaluating the effects on NMC. The reported BM purification process is then demonstrated on samples of "simulated BM" containing a practically relevant 1 wt% concentration of Al or Cu. Increasing the kinetic energy of the purifying solution matrix through elevated temperature and sonication accelerates the corrosion of metallic Al and Cu, such that ∼100% corrosion of 75 μm Al and Cu particles is achieved within 2.5 hr. Further, we determine that effective mass transport of ionized species critically impacts the efficacy of Cu corrosion, and that saturated Cl^- hinders rather than accelerates Cu corrosion by increasing solution viscosity and introducing competitive pathways for Cu surface passivation. The purification conditions do not induce bulk structural damage to NMC, and electrochemical capacity is maintained in half-cell format. Testing in full cells suggests that a limited quantity of residual surface species are present after treatment, which initially disrupt electrochemical behavior at the graphite anode but are subsequently consumed. Process demonstration on simulated BM suggests that contaminated samples-which prior to treatment show catastrophic electrochemical performance-can be recovered to pristine electrochemical capacity. The reported BM purification method offers a compelling and commercially viable solution to address contamination, particularly in the "fine" fraction of BM where contaminant sizes are on the same order of magnitude as NMC and where traditional separation approaches are unfeasible. Thus, this optimized BM purification technique offers a pathway towards viable direct recycling of BM feedstocks that would otherwise be unusable.

Worldwide research on extraction and recovery of cobalt through bibliometric analysis: a review

Cobalt is a strategic and critical mineral whose demand is expected to grow rapidly. This study aims to provide a comprehensive summary of cobalt extraction and recovery research from 2012 to 2021 in the form of bibliometric analysis. The work was based on the Science Citation Index Expanded (Web of Science) and carried out using the InCites of Clarivate for bibliometric data analysis and the software VOSviewer for science mapping. By analyzing a dataset of 4967 publications, the most influential journals, countries, authors, institutions, and publications were identified, and the keyword co-occurrence networks were mapped. The China mainland produced the most publications, while the USA had the highest average number of citations per publication and the UK was the most collaborative with other countries. The keyword analysis shows that the research hotspots gradually shifted over time from early means and methods for determination of cobalt in solution to recovery of cobalt from spent lithium batteries, smelting slag, copper-cobalt ore, etc. The research will be focused on further improvement and optimization of the separation, extraction, and recovery processes of cobalt from spent batteries in recent and future years, and three approaches were promoted to facilitate economization and industrialization of the processes in this field.

Single-Stage Extraction and Separation of Co2+ from Ni2+ Using Ionic Liquid of [C4H9NH3][Cyanex 272]

The purpose of this study was to optimize the extraction conditions for separating Co²⁺ from Ni²⁺ using N-butylamine phosphinate ionic liquid of [C₄H₉NH₃][Cyanex 272]. A Box–Behnken design of response surface methodology was used to analyze the effects of the initial pH, extraction time, and extraction temperature on the separation factor of Co²⁺ from sulfuric acid solution containing Ni²⁺. The concentrations of Co²⁺ and Ni²⁺ in an aqueous solution were determined using inductively coupled plasma-optical emission spectrometry. The optimized extraction conditions were as follows: an initial pH of 3.7, an extraction time of 55.8 min, and an extraction temperature of 330.4 K. The separation factor of Co²⁺ from Ni²⁺ under optimized extraction conditions was 66.1, which was very close to the predicted value of 67.2, and the error was 1.7%. The equation for single-stage extraction with high reliability can be used for optimizing the multi-stage extraction process of Co²⁺ from Ni²⁺. The stoichiometry of chemical reaction for ion-exchange extraction was also investigated using the slope method.

Cobalt Recovery from Li-Ion Battery Recycling: A Critical Review

The increasing demand for Li-ion batteries for electric vehicles sheds light upon the Co supply chain. The metal is crucial to the cathode of these batteries, and the leading global producer is the D.R. Congo (70%). For this reason, it is considered critical/strategic due to the risk of interruption of supply in the short and medium term. Due to the increasing consumption for the transportation market, the batteries might be considered a secondary source of Co. The outstanding amount of spent batteries makes them to a core of urban mining warranting special attention. Greener technologies for Co recovery are necessary to achieve sustainable development. As a result of these sourcing challenges, this study is devoted to reviewing the techniques for Co recovery, such as acid leaching (inorganic and organic), separation (solvent extraction, ion exchange resins, and precipitation), and emerging technologies—ionic liquids, deep eutectic solvent, supercritical fluids, nanotechnology, and biohydrometallurgy. A dearth of research in emerging technologies for Co recovery from Li-ion batteries is discussed throughout the manuscript within a broader overview. The study is strictly connected to the Sustainability Development Goals (SDG) number 7, 8, 9, and 12.

Phase transfer of metal cations by induced dynamic carrier agents: biphasic extraction based on dynamic covalent chemistry

In contrast to the classical method where a single molecule is designed to extract metal cations under specific conditions, dynamic covalent chemistry provides an approach based on the implementation of an adaptive dynamic covalent library for inducing the generation of the extractant species. This approach has been applied to the liquid-liquid extraction of copper(ii) nitrate based on a dynamic library of acylhydrazones constituents that self-build and distribute through the interface of a biphasic system. The addition of copper(ii) cations to this library triggers a modification of its composition and the up-regulation of the ligand molecules driven by coordination to the metal cations. Among these, one species has proven to be sufficiently lipophilic to play the role of carrier agent and its formation by component exchange enables the partial extraction of the copper(ii). The study of different pathways to generate the dynamic covalent library demonstrates the complete reversibility and the adaptability of the system. The detailed analytical investigation of the system provides a means to assess the mechanism of the dynamic extraction process.

Co(II) and Ni(II) transport from model and real sulfate solutions by extraction with bis(2,4,4-trimethylpentyl)phosphinic acid (Cyanex 272)

This paper presents the results of Co(II) and Ni(II) extraction from model and real solutions using bis(2,4,4-trimethylpentyl)phosphinic acid (i.e. Cyanex 272) that are in agreement with waste-to-resources approach, i.e. the recovery of valuable components from wastes. The results from this study shows that, extraction using Cyanex 272 is an efficient method to recover Co(II) selectively from sulfate electrolytes obtained from the leaching of steel scraps of aircraft engines. The highest selectivity value (∼160) of Co(II) extraction over Ni(II) was obtained at a pH of 4.8, the lowest selectivity value (∼30) was observed at a pH of 5.5, while above this value the selectivity only increased slightly with increasing pH. A pH of 5.2 was selected as a compromise between Co(II) selectivity and Ni(II) amount in the organic phase. The essence of the investigation is to propose important parameters to extract Co(II) from real leach solutions, and to further recover valuable Co(II) from the loaded organic phase by stripping with 1 M H₂SO₄, thus producing an electrolyte of Co(II) for electrowinning - a possible alternative route for resource recovery. Small volume of the stripping phase (w/o = 1:5) used in this study, lead to an enrichment of sulfate electrolyte in Co(II), resulting in ∼50 g/dm³ of Co(II) in the solution, which is a great advantage of the approach proposed. Such a solution is a valuable source for the electrowinning of metallic cobalt, which can be used for the production of steel alloys, Li-ion batteries or catalysts.

Pyrolysis and physical separation for the recovery of spent LiFePO4 batteries

In this study, a novel process consisting of pyrolysis and physical separation was proposed to comprehensively recycle spent lithium ion batteries (LIBs). The discharge and pyrolysis behaviors of spent LIBs, the recovery of electrolyte from the spent LIBs by low-temperature volatilization, and the recovery of valuable materials from the pyrolytic residues through physical separation were studied in detail. The results indicated that approximately 99.91% of the organic electrolytes was recycled, and the lithium salt (LiPF₆) in the batteries was disposed by pyrolysis process. The active materials could be effectively separated from current collectors after the pyrolysis under N₂ at 550 °C for 2 h. The pyrolytic gas was mainly composed of light alkenes, and the pyrolytic tar was mainly composed of aromatic long chain alkenes and light alcohols. Pyrolytic residues were recycled by color sorting, high-pressure water cleaning and flotation processes, and about 99.34% of Al, 96.25% of Cu, and 49.67% of cathode active materials were recovered from the spent LIBs. Finally, electrochemical tests indicate that the cathode active materials obtained by the process can be used to produce new batteries.

Extraction of cobalt(ii) by methyltrioctylammonium chloride in nickel(ii)-containing chloride solution from spent lithium ion batteries

Spent lithium batteries contain valuable metals such as cobalt, copper, nickel, lithium, etc. After pretreatment and recovery of copper, only cobalt, nickel and lithium were left in the acid solution. Since the chemical properties of cobalt and nickel are similar, separation of cobalt from a solution containing nickel is technically challenging. In this study, Co(ii) was separated from Ni(ii) by chelating Co(ii) with chlorine ions, Co(ii) was then extracted from the aforementioned chelating complexes by methyltrioctylammonium chloride (MTOAC). The effects of concentrations of chlorine ions in the aqueous phase ([Cl⁻]_aq), MTOAC concentrations in organic phase ([MTOAC]_org), ratios of organic phase to aqueous phase (O/A), and the initial aqueous pH on cobalt separation were studied. The results showed that [Cl⁻]_aq had a significant impact on cobalt extraction efficiency with cobalt extraction efficiency increasing rapidly with the increase in [Cl⁻]_aq. The effect of initial pH on cobalt extraction efficiency was not significant when it varied from 1 to 6. Under the condition of [Cl⁻]_aq = 5.5 M, [MTOAC]_org = 1.3 M, O/A = 1.5, and pH = 1.0, cobalt extraction efficiency reached the maximum of 98.23%, and nickel loss rate was only 0.86%. The stripping rate of cobalt from Co(ii)–MTOAC complexes using diluted hydrochloric acid was 99.95%. By XRD and XRF analysis, the recovered cobalt was in the form of cobalt chloride with the purity of cobalt produced reaching 97.7%. The mode of cobalt extraction was verified to be limited by chemical reaction and the kinetic equation for cobalt extraction was determined to be: R_(Co) = 4.7 × 10⁻³[MTOAC]_(org)^1.85[Co]_(aq)^1.25.

Interception of dearomatized tertiary boronic ester in a diastereoselective [4 + 2] cycloaddition or 1,3-borotopic shift in the presence or absence of “naked” Li⁺, understanding reactivities by activation/strain model, were evaluated by DFT calculations.

Impurity removal with highly selective and efficient methods and the recycling of transition metals from spent lithium-ion batteries

A strategy for metal purification and recovery from spent lithium-ion batteries is demonstrated by taking advantage of precipitation, electrodeposition and solvent extraction.

Ultrasound-assisted leaching of cobalt and lithium from spent lithium-ion batteries

Recovery of cobalt and lithium from spent Li-ion batteries (LIBs) has been studied using ultrasound-assisted leaching. The primary purpose of this work is to investigate the effects of ultrasound on leaching efficiency of cobalt and lithium. The results were compared to conventional leaching. In this study sulfuric acid was used as leaching agent in the presence of hydrogen peroxide. The cathode active materials from spent battery were characterized by X-ray diffraction (XRD) and scanning electron microscopy (SEM) before and after leaching. Effects of leaching time, leaching temperature, H₂SO₄ concentration, H₂O₂ concentration, solid/liquid ratio, and ultrasonic power have been studied. Optimal leaching efficiency of 94.63% for cobalt, and 98.62% for lithium, respectively, was achieved by using 2 M H₂SO₄ with 5% (v/v) H₂O₂ at a solid/liquid ratio of 100 g/L, and an ultrasonic power of 360 W, and the leaching time being 30 min under 30 °C. Compared with conventional leaching, the ultrasound-assisted leaching gave a higher leaching rate and improved leaching efficiency under the same experimental conditionals. The kinetic analysis of ultrasound-assisted leaching showed that the activation energy of cobalt and lithium were 3.848 KJ/mol and 11.6348 KJ/mol, respectively, indicating that ultrasound-assisted leaching of cobalt and lithium from spent LIBs was controlled by diffusion.

The impact of aluminum impurity on the regenerated lithium nickel cobalt manganese oxide cathode materials from spent LIBs

An effective recycling process from spent LIBs has been developed, and the tolerability of aluminum was studied in this work.

Recovery of cobalt from spent lithium ion batteries using sulphuric acid leaching followed by solid–liquid separation and solvent extraction

Herein, the method of hydrometallurgy is adopted to recycle the precious metal cobalt in spent lithium ion batteries (LIBs).