Separation and recovery of metal values from leach liquor of waste lithium nickel cobalt manganese oxide based cathodes

A feasible process for recycling valuable metals from LiNi0.5Co0.2Mn0.3O2 cathode materials of spent Li-ion batteries

The recycling of cathode materials for spent NCM has always been a major concern for the energy industry. However, among the current processing methods, the general leaching efficiency of Li is between 85% and 93%, with much room for improvement. The recovery of Ni, Co and Mn requires a high cost of secondary purification. In this study, to recycle the NCM cathode material, a route of sulphated reduction roasting - selective Li water leaching - efficiency acid leaching of Ni, Co, Mn - extraction separation - crystallisation was adopted. The results showed that after roasting (a temperature of 800 °C, a reaction time of 90 min, a carbon content of 26%, and a sulphuric acid addition of nH2SO4:nLi = 0.85), Li water leaching efficiency was 98.6%, followed by acid leaching of Ni, Co and Mn at around 99%. Mn, Co were extracted with Di-(2-ethylhexyl) phosphoric acid and 2-Ethylhexyl phosphonic acid mono-2-ethylhexyl ester respectively to obtain Ni, Co, Mn solutions, which eventually were crystallized for manganese sulphate, cobalt sulphate, lithium carbonate and nickel sulphate products, with high purity of 99.40%, 98.95%, 99.10%, and 99.95%. The results of this study improved the leaching efficiency of Li and were closely linked to the actual industrial preparation of Ni, Co and Mn sulphates, providing a feasible and promising basis for spent NCM cathode materials industrial recovery.

Facile Gram-Scale Synthesis of Co3O4 Nanocrystal from Spent Lithium Ion Batteries and Its Electrocatalytic Application toward Oxygen Evolution Reaction

In this study, we demonstrate a new approach to easily prepare spinel Co₃O₄ nanoparticles (s-Co₃O₄ NPs) in the gram-scale from the cathode of spent lithium ion batteries (SLIBs) by the alkali leaching of hexaamminecobalt(III) complex ions. As-obtained intermediate and final products were characterized with powder X-ray diffraction (PXRD), Ultraviolet-Visible (UV-Vis), Fourier transform infrared (FTIR), and Transmission electron microscopy (TEM). Additionally, the synthesized s-Co₃O₄ NPs showed better electrocatalytic properties toward the oxygen evolution reaction (OER) in comparison to previously reported Co₃O₄ NPs and nanowires, which could be due to the more exposed electrocatalytic active sites on the s-Co₃O₄ NPs. Moreover, the electrocatalytic activity of the s-Co₃O₄ NPs was comparable to the previously reported RuO₂ catalysts. By taking advantage of the proposed recycling route, we would expect that various valuable transition metal oxide NPs could be prepared from SLIBs.

The Efficiency of Black Mass Preparation by Discharge and Alkaline Leaching for LIB Recycling

Lithium-ion batteries (LIBs) are dangerous to recycle, as they pose a fire hazard when cut and contain various chemical hazards. If recycled safely, LIBs provide a rich secondary source for metals such as lithium and cobalt, while reducing the environmental impact of end-of-life LIBs. Discharging the spent LIBs in a 5 wt.% NaCl electrolyte at room temperature enables their safe dismantling. A sludge was observed to form during the LIB discharging, with a composition of 34.9 wt.% Fe, 35 wt.% O, 17.7 wt.% Al, 6.2 wt.% C, and 4.2 wt.% Na. The average electrolytic solution composition after the first discharge cycle contained only 12.6 mg/L Fe, 4.5 mg/L Li, 2.5 mg/L Mn, and trace amounts of Ni and Co. Separating the active cathode powder from the aluminum cathode with a 10 wt.% NaOH leach produced an aqueous filtrate with an Al metal purity of 99.7%. The leach composition consisted of 9558 mg/L Al, 13 mg/L Li, 8.7 mg/L Co, and trace amounts of Mn and Ni. The hydrometallurgical sample preparation processes in this study enables the production of a pure black mass with less than 0.05 wt.% Co, 0.2 wt.% Li, 0.02 wt.% Mn, and 0.02 wt.% Ni losses from the active cathode material.

Reaction mechanism of antibiotic bacteria residues as a green reductant for highly efficient recycling of spent lithium-ion batteries

In this study, antibiotic bacteria residues (ABRs) is proposed as a novel green reducing agent and it is found that the reducing agent can realize the efficient recovery of the valuable metals in spent cathode powder (SCP), reduce the environmental pollution and realize the high-value utilization of the biomass waste. The leaching efficiency of Ni, Co, Mn and Li can reach 99.57%, 98.50%, 98.99% and 99.90% respectively under the optimal conditions of 3 mol L^-1 H₂SO₄, mass ratio of ABRs to SCP of 0.8:1, liquid/solid ratio of 30:1 mL g^-1, the temperature of 363 K and time of 2.5 h. Leaching kinetics results shows that the reaction process is controlled by the chemical reaction with apparent activation energy exceeding than 40 kJ/mol. More importantly, the detailed ABRs leaching mechanism is proposed that the metabolite of CaC₂O₄ and reducing sugar in ABRs provide a synergistic reduction effect on the recovery of valuable metals. Furthermore, acid leaching residue can be regenerated to obtain lithium-ion anode materials with excellent electrochemical properties. The entire process is a sustainable green recycling strategy by using waste ABRs waste to treat spent lithium-ion batteries (LIBs), recovering valuable metals efficiently and minimizing environmental pollution.

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.

Recycling and Direct-Regeneration of Cathode Materials from Spent Ternary Lithium-Ion Batteries by Hydrometallurgy: Status Quo and Recent Developments : Economic recovery methods for lithium nickel cobalt manganese oxide cathode materials

The cathodes of spent ternary lithium-ion batteries (LIBs) are rich in nonferrous metals, such as lithium, nickel, cobalt and manganese, which are important strategic raw materials and also potential sources of environmental pollution. Finding ways to extract these valuable metals cleanly and efficiently from spent cathodes is of great significance for sustainable development of the LIBs industry. In the light of low energy consumption, ‘green’ processing and high recovery efficiency, this paper provides an overview of different recovery technologies to recycle valuable metals from cathode materials of spent ternary LIBs. Development trends and application prospects for different recovery strategies for cathode materials from spent ternary LIBs are also predicted. We conclude that a highly economic recovery system: alkaline solution dissolution/calcination pretreatment → H2SO4 leaching → H2O2 reduction → coprecipitation regeneration of nickel cobalt manganese (NCM) will become the dominant stream for recycling retired NCM batteries. Furthermore, emerging advanced technologies, such as deep eutectic solvents (DESs) extraction and one‐step direct regeneration/recovery of NCM cathode materials are preferred methods to substitute conventional regeneration systems in the future.

A promising selective recovery process of valuable metals from spent lithium ion batteries via reduction roasting and ammonia leaching

In this study, a promising process has been developed for selective recovery of valuable metals from spent lithium ion batteries (LIBs). First, reduction roasting which used spent anode powder as reduction agent and water immersion are applied to preferentially recover lithium. Subsequently, an ammonia leaching method is adopted to eff ;ectively separate nickel and cobalt from water immersion residue. Results indicate that Li₂CO₃, (NiO)_m·(MnO)_n, Ni, Co are the ultimate reduction products at 650 °C for 1 h with 5% anode powder. 82.2 % Li is preferentially leached via water immersion after reduction roasting and Li₂CO₃ products are obtained by evaporation crystallization. Thermodynamics shows that reducing ammonia leaching is feasible for water immersion residue. Amounts of 97.7 % Ni and 99.1 % Co can be selectively leached by NH_3·H₂O and (NH₄)₂SO₃ while Mn remain in the residue as (NH₄)₂Mn(SO₃)_2·H₂O, (NH₄)₂Mn(SO₄)_2·6H₂O and (NH₄)₂Mn₂(SO₃)₃ under the optimized conditions. Ammonia leaching kinetic show the activation energy of Ni and Co is 84.44 kJ/mol and 91.73 kJ/mol, which indicate the controlling steps are the chemical reaction. Summarily, the whole process achieves the maximum degree of selective recovery and reduces the environmental pollution caused by the multistep purification.

Optimization of Manganese Recovery from a Solution Based on Lithium-Ion Batteries by Solvent Extraction with D2EHPA

Manganese is a critical metal for the steelmaking industry, and it is expected that its world demand will be increasingly affected by the growing market of lithium-ion batteries. In addition to the increasing importance of manganese, its recycling is mainly determined by trends in the recycling of iron and steel. The recovery of manganese by solvent extraction has been widely investigated; however, the interaction of different variables affecting the process is generally not assessed. In this study, the solvent extraction of manganese from a solution based on lithium-ion batteries was modeled and optimized using factorial designs of experiments and the response surface methodology. Under optimized conditions (O:A of 1.25:1, pH 3.25, and 0.5 M bis(2-ethylhexyl) phosphoric acid (D2EHPA)), extractions above 70% Mn were reached in a single extraction stage with a coextraction of less than 5% Co, which was mostly removed in two scrubbing stages. A stripping product containing around 23 g/L Mn and around 0.3 g/L Co can be obtained under optimized conditions (O:A of 8:1, 1 M H2SO4 and around 13 min of contact time) in one stripping stage.

Selective Precipitation of Metal Oxalates from Lithium Ion Battery Leach Solutions

The separation of cobalt and nickel from sulfatic leach liquors of spent lithium-ion batteries is described in this paper. In addition to the base metals (e.g., cobalt and nickel), components such as manganese and lithium are also present in such leach liquors. The co-precipitation of these contaminants can be prevented during leach liquor processing by selective precipitation. For the recovery of a cobalt-nickel mixed material, oxalic acid serves as a suitable reagent. For the optimization of the precipitation retention time and yield, the dependence of the oxalic acid addition must be taken into account. In addition to efficiency, attention must also be given to the purity of the product. After this procedure, further processing of the products by calcination into oxides leads to better marketability. A series of experiments confirms the suitability of oxalic acid for precipitation of cobalt and nickel as a mixed oxalate from sulfatic liquors and also suggests a possible route for further processing of the products with increased marketability. The impurities in the resulting oxides are below 3%, whereby a sufficiently high purity of the mixed oxide can be achieved.

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.

Advances in mineral processing technologies related to iron, magnesium, and lithium

Exploitation and utilization of mineral resources have played a vital role in China’s rapid economic developments. Although the history of mineral processing is quite long, technologies in this field have varied with the changes of market demands. This is particularly the case for minerals whose high-grade deposits are depleting. The aim of this review is to present our recent efforts on developing new routes for the utilization of low-grade minerals, such as iron ores and brine-containing lithium. The emphasis on the two minerals lies in the fact that iron plays a vital role in modern-day civilization and lithium is a key component in electric vehicles for transportation. Furthermore, the utilization of magnesium chloride reserves, one of the largest wastes in western China, as raw materials for fabrication of functional materials is also included in this review.

Recovery of valuable metals from LiNi0.5Co0.2Mn0.3O2 cathode materials of spent Li-ion batteries using mild mixed acid as leachant

A novel hydrometallurgical process for recycling LiNi_0.5Co_0.2Mn_0.3O₂ cathode materials harvested from spent Li-ion batteries (LIBs) is established in this work. The cathode material LiNi_0.5Co_0.2Mn_0.3O₂ is dissolved in a mixed acid containing phosphoric acid (leaching agent) and citric acid (leaching agent and reductant). Using 0.2 M phosphoric acid and 0.4 M citric acid with a solid to liquid (S/L) ratio of 20 g/L at 90 °C for 30 min, the proposed method results in a leaching efficiency of ca. 100% for Li, 93.38% for Ni, 91.63% for Co, and 92.00% for Mn, respectively. Kinetics of the leaching process is well described by the Avrami equation. It is found that the leaching process is controlled by surface chemical reactions, and the apparent activation energies (kJ/mol) are 45.83 for Li, 83.01 for Ni, 81.38 for Co and 92.35 for Mn, respectively. With aids of various advanced characterizations methods, including UV-Vis, FT-IR and TOC, we find that there are a great deal of citrates and a small amount of dihydrogen phosphates in the mixed acid leachate. This leaching method enjoys advantages of low acid consumption, short leaching time and no need to add extra reductant.

Organic reductants based leaching: A sustainable process for the recovery of valuable metals from spent lithium ion batteries

It is significant to recover metal values from spent lithium ion batteries (LIBs) for the alleviation or prevention of potential risks towards environmental pollution and public health, as well as for the conservation of valuable metals. Herein a hydrometallurgical process was proposed to explore the possibility for the leaching of different metals from waste cathodic materials (LiCoO₂) of spent LIBs using organics as reductant in sulfuric acid medium. According to the leaching results, about 98% Co and 96% Li can be leached under the optimal experimental conditions of reaction temperature - 95 °C, reaction time - 120 min, reductive agent dosage - 0.4 g/g, slurry density - 25 g/L, concentration of sulfuric acid-3 mol/L in H₂SO₄ + glucose leaching system. Similar results (96% Co and 100% Li) can be obtained in H₂SO₄ + sucrose leaching system under optimized leaching conditions. Despite a complete leaching of Li (∼100%), only 54% Co can be dissolved in the H₂SO₄ + cellulose leaching system under optimized leaching conditions. Finally, different characterization methods, including UV-Vis, FT-IR, SEM and XRD, were employed for the tentative exploration of reductive leaching reactions using organic as reductant in sulfuric acid medium. All the leaching and characterization results confirm that both glucose and sucrose are effective reductants during leaching, while cellulose should be further degraded to organics with low molecular weights to achieve a satisfactory leaching performance.

Sustainable recovery of valuable metals from spent lithium-ion batteries using DL-malic acid: Leaching and kinetics aspect

An eco-friendly and benign process has been investigated for the dissolution of Li, Co, Ni, and Mn from the cathode materials of spent LiNi_1/3Co_1/3Mn_1/3O₂ batteries, using DL-malic acid as the leaching agent in this study. The leaching efficiencies of Li, Co, Ni, and Mn can reach about 98.9%, 94.3%, 95.1%, and 96.4%, respectively, under the leaching conditions of DL-malic acid concentration of 1.2 M, hydrogen peroxide content of 1.5 vol.%, solid-to-liquid ratio of 40 g l^-1, leaching temperature of 80°C, and leaching time of 30 min. In addition, the leaching kinetic was investigated based on the shrinking model and the results reveal that the leaching reaction is controlled by chemical reactions within 10 min with activation energies (Ea) of 21.3 kJ·mol^-1, 30.4 kJ·mol^-1, 27.9 kJ·mol^-1, and 26.2 kJ·mol^-1 for Li, Co, Ni, and Mn, respectively. Diffusion process becomes the controlled step with a prolonged leaching time from 15 to 30 min, and the activation energies (Ea) are 20.2 kJ·mol^-1, 28.9 kJ·mol^-1, 26.3 kJ·mol^-1, and 25.0 kJ·mol^-1 for Li, Co, Ni, and Mn, respectively. This hydrometallurgical route was found to be effective and environmentally friendly for leaching metals from spent lithium batteries.

Study on the mechanism of copper-ammonia complex decomposition in struvite formation process and enhanced ammonia and copper removal

Heavy metals and ammonia are difficult to remove from wastewater, as they easily combine into refractory complexes. The struvite formation method (SFM) was applied for the complex decomposition and simultaneous removal of heavy metal and ammonia. The results indicated that ammonia deprivation by SFM was the key factor leading to the decomposition of the copper-ammonia complex ion. Ammonia was separated from solution as crystalline struvite, and the copper mainly co-precipitated as copper hydroxide together with struvite. Hydrogen bonding and electrostatic attraction were considered to be the main surface interactions between struvite and copper hydroxide. Hydrogen bonding was concluded to be the key factor leading to the co-precipitation. In addition, incorporation of copper ions into the struvite crystal also occurred during the treatment process.