A hydrometallurgical process for the separation of aluminum, cobalt, copper and lithium in acidic sulfate media

Comparative life cycle analysis of critical materials recovery from spent Li-ion batteries

The development of new generations of electric vehicles is expected to drive the growth of lithium-ion batteries in the global market. Life Cycle Assessment (LCA) method was utilized in this study to evaluate the environmental impacts of various hydrometallurgical processes in critical materials recovery from lithium-ion battery (LIB) cathode powder. The main objective of this work was to fill the knowledge gap regarding the environmental sustainability of various processes in LIB recycling and to generate a comprehensive comparison of the environmental burdens caused by numerous hydrometallurgical methods. According to this investigation, leaching with acetic acid, formic acid, maleic acid, and DL-malic acid demonstrates lower environmental impacts compared to lactic acid, ascorbic acid, succinic acid, citric acid, trichloroacetic acid, and tartaric acid. Among inorganic acids, nitric acid and hydrochloric acid show higher environmental impacts compared to sulfuric acid. Furthermore, the results of this study indicate that leaching with some organic acids such as citric, succinic, ascorbic, trichloroacetic, and tartaric acids leads to higher negative environmental impacts in most environmental categories compared to inorganic acids like sulfuric and hydrochloric acid. Therefore, not all organic acids utilized in the leaching of critical and strategic materials from cathode powder can enhance environmental sustainability in the recycling process. The results of the solvent extraction study as a downstream process of leaching show that sodium hydroxide, organic reagents, and kerosene have the highest environmental impact among all inputs in this process. Generally, solvent extraction has a greater environmental impact compared to the leaching process.

Deep eutectic solvent for spent lithium-ion battery recycling: comparison with inorganic acid leaching

Deep eutectic solvents (DESs) as novel green solvents are potential options to replace inorganic acids for hydrometallurgy. Compared with inorganic acids, the physicochemical properties of DESs and their applications in recycling of spent lithium-ion batteries were summarized. The viscosity, metal solubility, toxicological properties and biodegradation of DESs depend on the hydrogen bond donor (HBD) and acceptor (HBA). The viscosity of ChCl-based DESs increased according to the HBD in the following order: alcohols < carboxylic acids < sugars < inorganic salts. The strongly coordinating HBDs increased the solubility of metal oxide via surface complexation reactions followed by ligand exchange for chloride in the bulk solvent. Interestingly, the safety and degradability of DESs reported in the literature are superior to those of inorganic acids. Both DESs and inorganic acids have excellent metal leaching efficiencies (>99%). However, the reaction kinetics of DESs are 2-3 orders of magnitude slower than those of inorganic acids. A significant advantage of DESs is that they can be regenerated and recycled multiple times after recovering metals by electrochemical deposition or precipitation. In the future, the development of efficient and selective DESs still requires a lot of attention.

Evaluation of leaching characteristic and kinetic study of lithium from lithium aluminum silicate glass-ceramics by NaOH

The behavior and mechanism of Li leaching from lithium aluminum silicate glass-ceramics which can be used as a secondary source of Li using aqueous NaOH solution was investigated. The Li leaching efficiency is increased with increasing concentration of NaOH, specific surface area, and reaction temperature. When leached under optimum conditions, 2 mol/L NaOH, 53 μm particle undersize, 1:10 solid/liquid ratio, 250 r/min stirring speed, 100°C reaction temperature, 12 hr, the Li leaching efficiency was approximately 70%. However, when the leaching experiment was performed for 48 hr, the concentration of Li⁺ ions contained in the leach liquor decreased from 1160 to 236 mg/L. To investigate the origin of this phenomenon, the obtained leach residue was analyzed by X-ray diffraction, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. These analyses show that zeolite was formed around the lithium aluminum silicate glass-ceramics, which affected the leaching of by adsorbing Li⁺ ions. In addition, using the shrinking-core model and the Arrhenius equation, the leaching reaction with NaOH was found to depends on the chemical reaction of the two reactants, with a higher than 41.84 kJ/mol of the activation energy.

Recovery of cathode materials from spent lithium-ion batteries and their application in preparing multi-metal oxides for the removal of oxygenated VOCs: Effect of synthetic methods

Due to the sustainable use of wastes, cathode materials of spent lithium-ion batteries are recovered and used as transition metal precursors to prepare metal oxides catalysts for the oxidation of VOCs. In this work, a series of manganese-based and cobalt-based metal oxides are synthesized via different preparation methods. Catalytic activities of the catalysts prepared are investigated through complete oxidation of oxygenated VOCs and the physicochemical properties of optimum samples are characterized. Evaluation results indicate that MnOx (SY) (HT) sample prepared via hydrothermal method and CoOx (GS) (CP) synthesized via co-precipitation method had better performance, because they have higher specific surface area, higher concentration of active oxygen species and high-valence metal ion, as well as better low-temperature reducibility compared to the other multi-metal oxides used in the study. In addition, TD/GC-MS results imply that further oxidation of by-products requires high reaction temperature during VOCs oxidation.

Low-temperature thermal pretreatment process for recycling inner core of spent lithium iron phosphate batteries

Spent lithium iron phosphate (LFP) batteries contain abundant strategic lithium resources and are thus considered attractive secondary lithium sources. However, these batteries may contaminate the environment because they contain hazardous materials. In this work, a novel process involving low-temperature heat treatment is used as an alternative pretreatment method for recycling spent LFP batteries. When the temperature reaches 300°C, the dissociation effect of the anode material gradually improves with heat treatment time. At the heat treatment time of 120 minutes, an electrode material can be dissociated. The extension of heat treatment time has a minimal effect on quality loss. The physicochemical changes in thermally treated solid cathode and anode materials are examined through scanning electron microscopy with energy-dispersive X-ray spectroscopy. The heat treatment results in the complete separation of the materials from aluminium foil without contamination. The change in heat treatment temperature has a small effect on the quality of LFP material shedding. When the heat treatment temperature reaches 300°C and the time reaches 120 minutes, heat treatment time increases, and the yield of each particle size is stable and basically unchanged. The method can be scaled up and may reduce environmental pollution due to waste LFP batteries.

Recovery of valuable metals from mixed spent lithium-ion batteries by multi-step directional precipitation

The novel strategy of multi-step directional precipitation is proposed for recovering valuable metals from the leachate of cathode material obtained by mechanical disassembly from mixed spent lithium-ion batteries. Based on thermodynamics and directional precipitation, Mn²⁺ is selectively precipitated under conditions of MRNM (molar ratio of (NH₄)₂S₂O₈ to Mn²⁺) = 3, pH = 5.5 and 80 °C for 90 min. Ni²⁺ was then selectively precipitated using C₄H₈N₂O₂ under conditions of pH = 6, MRCN (molar ratio of C₄H₈N₂O₂ to Ni²⁺) = 2, 30 °C and 20 min. Then, the pH was adjusted to 10 to precipitate Co²⁺ as Co(OH)₂. Finally, Li⁺ was recovered by Na₂CO₃ at 90 °C. The precipitation rates of Mn, Ni, Co, and Li reached 99.5%, 99.6%, 99.2% and 90%, respectively. The precipitation products with high purity can be used as raw materials for industrial production based on characterization. The economical and efficient recovery process can be applied in industrialized large-scale recycling of spent lithium-ion batteries.

A Comprehensive Review of Li-Ion Battery Materials and Their Recycling Techniques

In the context of constant growth in the utilization of the Li-ion batteries, there was a great surge in the quest for electrode materials and predominant usage that lead to the retiring of Li-ion batteries. This review focuses on the recent advances in the anode and cathode materials for the next-generation Li-ion batteries. To achieve higher power and energy demands of Li-ion batteries in future energy storage applications, the selection of the electrode materials plays a crucial role. The electrode materials, such as carbon-based, semiconductor/metal, metal oxides/nitrides/phosphides/sulfides, determine appreciable properties of Li-ion batteries such as greater specific surface area, a minimal distance of diffusion, and higher conductivity. Various classifications of the anode materials such as the intercalation/de- intercalation, alloy/de-alloy, and various conversion materials are illustrated lucidly. Further, the cathode materials, such as nickel-rich LiNixCoyMnzO2 (NCM), were discussed. NCM members such as NCM 333, NCM 523 that enabled to advance for NCM622 and NCM81are reported. The nanostructured materials bridged the gap in the realization of next-generation Li-ion batteries. Li-ion batteries’ electrode nanostructure synthesis, performance, and reaction mechanisms were considered with great concern. The serious effects of Li-ion batteries disposal need to be cut significantly to reduce the detrimental effect on the environment. Hence, the recycling of spent Li-ion batteries has gained much attention in recent years. Various recycling techniques and their effect on the electroactive materials are illustrated. The key areas covered in this review are anode and cathode materials and recent advances along with their recycling techniques. In light of crucial points covered in this review, it constitutes a suitable reference for engineers, researchers, and designers in energy storage applications.

Efficient process for recovery of waste LiMn2O4 cathode material precipitation thermodynamic analysis and separation experiments

An efficient process is proposed for recovery of waste LiMn₂O₄ cathode material, which is one of the most commonly used cathode materials in LIBs. This report constitutes the precipitation thermodynamic analysis and separation experiments based on the water-leaching solutions during the processes of low-temperature calcination with (NH₄)₂SO₄ and water-leaching. Precipitation thermodynamic analysis is undertaken to investigate the effects of initial concentration of the target solution, [N]_T1, excess precipitant, and addition of (NH₄)₂SO₄ on the manganese precipitation in the Mn²⁺-Li⁺-SO₄^2--NH₃-NH₄⁺-CO₃^2--H₂O system. Moreover, the effects of initial concentration of the target solution, [N]_T2, and excess precipitant on the lithium precipitation in the Li⁺-SO₄^2--NH₃-NH₄⁺-CO₃^2--H₂O system are investigated. All these factors clearly influence the manganese and lithium precipitation, particularly the [N]_T and the presence of excess precipitant in the system. The precipitation experimental results demonstrate that the optimal conditions are: a precipitation temperature of 35 °C; an excess coefficient of the precipitant of 2.4; the use of NHC-3 to precipitate the ML-3 solution; a maximum precipitation percentage of manganese of 99.96%; and an absence of Li₂CO₃ precipitation. The double-sulfate salts (Li(NH₄)SO₄ & (NH₄)₂SO₄) evaporated and crystallised from the Li⁺/NH₄⁺ solution are mixed with the waste LiMn₂O₄ cathode material for calcination and water leaching, for which the efficiencies of Li and Mn are 100% and 96.89%, respectively. The double-sulfate salts are calcined at 550 °C for 45 min to obtain the Li₂SO₄ product. Finally, the complete recovery and separation of Mn and Li in the waste LiMn₂O₄ cathode material are achieved.

Conversion Mechanisms of Selective Extraction of Lithium from Spent Lithium-Ion Batteries by Sulfation Roasting

With the undergoing unprecedented development of lithium-ion batteries (LIBs), the recycling of end-of-life batteries has become an urgent task considering the demand for critical materials, environmental pollution, and ecological impacts. Selective recovery of targeted element(s) is becoming a topical field that enables metal recycling in a short path with highly improved material efficiencies. This research demonstrates a process of selective recovery of spent Ni-Co-Mn (NCM)-based lithium-ion battery by systematically understanding the conversion mechanisms and controlling the sulfur behavior during a modified-sulfation roasting. As a result, Li from complex cathode components can be selectively extracted with high efficiency by only using water. Notably, the sulfur driven recovery processes can be divided into two stages: (i) part of the structure of NCM523 was destroyed, and Ni, Co, and Mn were reduced to divalent in different degrees to form sulfate (NiSO₄, CoSO₄, MnSO₄) when reacting with H₂SO₄ at ambient temperature; (ii) with increasing temperature, Li ions in the unstable layered structure are released and combined with SO₄^2- in the transition metal sulfate to form Li₂SO₄, and the sulfates of transition metals react to form Ni_0.5Co_0.2Mn_0.3O_1.4. Studies have shown sulfur can be recirculated thoroughly in the form of SO₄^2-, which in principle avoids secondary pollutions. By controlling the appropriate conversion temperature, we envisage that the sulfation selective roasting recovery technology could be easily applied to other spent lithium-ion battery materials. Besides, this work may also provide a unique platform for further study on the efficient extracting of other mineral resources.

Toward sustainable and systematic recycling of spent rechargeable batteries

A comprehensive and novel view on battery recycling is provided in terms of the science and technology, engineering, and policy.

Generation and detection of metal ions and volatile organic compounds (VOCs) emissions from the pretreatment processes for recycling spent lithium-ion batteries

The recycling of spent lithium-ion batteries brings benefits to both economic and environmental terms, but it can also lead to contaminants in a workshop environment. This study focused on metals, non-metals and volatile organic compounds generated by the discharging and dismantling pretreatment processes which are prerequisite for recycling spent lithium-ion batteries. After discharging in NaCl solution, metal contents in supernate and concentrated liquor were detected. Among results of condition #2, #3, #4 and #5, supernate and concentrated liquor contain high levels of Na, Al, Fe; middle levels of Co, Li, Cu, Ca, Zn; and low levels of Mn, Sn, Cr, Zn, Ba, K, Mg, V. The Hg, Ag, Cr and V are not detected in any of the analyzed supernate. 10wt% NaCl solution was a better discharging condition for high discharge efficiency, less possible harm to environment. To collect the gas released from dismantled LIB belts, a set of gas collecting system devices was designed independently. Two predominant organic vapour compounds were dimethyl carbonate (4.298mgh(-1)) and tert-amylbenzene (0.749mgh(-1)) from one dismantled battery cell. To make sure the concentrations of dimethyl carbonate under recommended industrial exposure limit (REL) of 100mgL(-1), for a workshop on dismantling capacity of 1000kg spent LIBs, the minimum flow rate of ventilating pump should be 235.16m(3)h(-1).

Leaching lithium from the anode electrode materials of spent lithium-ion batteries by hydrochloric acid (HCl)

Spent lithium-ion batteries (LIBs) are considered as an important secondary resource for its high contents of valuable components, such as lithium and cobalt. Currently, studies mainly focus on the recycling of cathode electrodes. There are few studies concentrating on the recovery of anode electrodes. In this work, based on the analysis result of high amount of lithium contained in the anode electrode, the acid leaching process was applied to recycle lithium from anode electrodes of spent LIBs. Hydrochloric acid was introduced as leaching reagent, and hydrogen peroxide as reducing agent. Within the range of experiment performed, hydrogen peroxide was found to have little effect on lithium leaching process. The highest leaching recovery of 99.4wt% Li was obtained at leaching temperature of 80°C, 3M hydrochloric acid and S/L ratio of 1:50g/ml for 90min. The graphite configuration with a better crystal structure obtained after the leaching process can also be recycled.