A closed-loop process for recycling LiNi1/3Co1/3Mn1/3O2 from the cathode scraps of lithium-ion batteries: Process optimization and kinetics analysis

Leaching behavior and kinetics of beryllium in beryllium-containing sludge (BCS)

Beryllium-containing sludge (BCS) is a byproduct of the physicochemical treatment of beryllium smelting wastewater. The pollutant element beryllium within BCS is highly unstable and extremely toxic, characterized by its small ionic radius and low charge density, resulting in a high risk of leaching and migration. This study is the first to investigate the leaching behavior, influencing mechanisms, and kinetic processes of beryllium in BCS under various environmental conditions. The results indicate that, under national standard conditions, beryllium exhibits a rapid leaching phase within the first 5 h, which then stabilizes after 10 h, with the total leached content significantly exceeding the leaching toxicity identification standards. Under mildly acidic (pH ≤ 5) or highly alkaline (pH = 14) conditions, beryllium demonstrates pronounced leaching and migration behaviors. Notably, in acidic conditions, the leaching rate exceeds 80% within 5 h. Combining the treatment process of beryllium-containing wastewater with analytical methods such as SEM, XPS, ToF-SIMS, and FTIR, it is revealed that due to the heterogeneous nature of BCS, the particle aggregates dissociate over time under acidic conditions. The particle surfaces become increasingly rough, leading to dissolution and the emergence of more reactive sites, resulting in a high proportion of beryllium leaching. Under these conditions, the gradual reaction of Be(OH)2 in BCS to form soluble Be2+ and its hydrolytic complexes is identified as the primary mechanism for extensive beryllium migration. The process encounters minimal diffusion resistance and is classified as reaction-controlled. In acidic conditions with pH = 4, the leaching rate of beryllium significantly increases with rising temperature. The leaching kinetics equation is [(1-x)-0.44]=e(18.26-53050RT)·t, with an apparent activation energy of 53.05 kJ mol-1.

Repurposing Kraft black Liquor as Reductant for Enhanced Lithium-Ion Battery Leaching

The economic advantages of H2SO4 make it the acid of choice for the hydrometallurgical treatment of waste lithium-ion batteries (LIBs). However, to facilitate the full dissolution of the higher valency metal oxides present in the cathode black mass, a suitable reducing agent is required. Herein, the application of industrial black liquor (BL) obtained from the Kraft pulping for papermaking is investigated as a renewable reducing agent for the enhanced leaching of transition metals from LIB powder with H2SO4. The addition of acidified BL to H2SO4 significantly improved the leaching efficiency for a range of LIB cathode chemistries, with the strongest effect observed for manganese-rich active material. Focusing on NMC111 (LiMnxCoyNizO2) material, a linear correlation between the BL concentration and the leaching yield of Mn was obtained, with the best overall leaching efficiencies being achieved for 2.0 mol L-1 H2SO4 and 50 vol % of BL at 353 K. A quasi-total degradation of oxygenated and aromatic groups from the BL during NMC111 dissolution was observed after leaching, suggesting that these chemical groups are essential for LIB reduction. Finally, the leached transition metals could be easily recovered by pH adjustment and oxalic acid addition, closing the resource loop and fostering resource efficiency.

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.

The Leaching Behavior of Potassium Extraction from Polyhalite Ore in Water

The extraction of potassium from polyhalite ore (K2SO4·MgSO4·2CaSO4·2H2O) can help alleviate potassium resource shortages in China. In this study, the leaching behavior of potassium extracted from polyhalite ore in water was investigated using leaching experiments and kinetic analysis. The effects of various factors, such as liquid-to-solid ratio, leaching temperature, leaching time, and polyhalite ore particle size were comprehensively studied. It was found that high temperatures improved the reaction rate and efficiency at the beginning (1-15 min) but reduced the final leaching efficiency of potassium. And this phenomenon is discussed from the aspects of the dissolution-reprecipitation of potassium, newly formed solid products during the leaching process, and leaching thermodynamics. The leaching of potassium followed the Avrami model, with an apparent activation energy of 26.29 kJ/mol. Additionally, it was determined that the mixed controlled step (surface chemical reaction and diffusion) was the controlling step during potassium leaching. This study clarified the leaching mechanism of the polyhalite in water, and the causes of hindering the leaching of potassium were analyzed. The research results can provide theoretical reference and solutions for parameter design for the enhanced leaching process and selection of leaching agents in the future.

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.

Novel strategy towards in-situ recycling of valuable metals from spent lithium-ion batteries through endogenous advanced oxidation process

Efficient and sustainable recycling of metal resources from spent lithium-ion batteries (LIBs) is critical for the metal resources security and environment protection. However, the intact exfoliation of cathode materials (CMs) from current collectors (Al foils) and selective extraction of Li towards the in-situ and sustainable recycling of cathodes from spent LIBs are still pending issues. A self-activated and ultrasonic-induced endogenous advanced oxidation process (EAOP) was proposed in this study for selective removal of PVDF and in-situ extraction of Li from CMs of waste LiFePO₄ (LFP) to address the above issues. Over 99 wt% CMs can be detached from Al foils after EAOP treatment under the optimized operation conditions. High purity of Al foil can be directly recycled as metallic forms and nearly 100 % of Li can be in-situ extracted from the detached CMs and then recovered as Li₂CO₃ (>99.9 % in purity). With induction and reinforcement of ultrasonic, S₂O₈^2- was self-activated by LFP to generate an increased amount of SO₄^•- radicals that will attack the PVDF binders to ensure their degradation. The degradation pathway of PVDF and density functional theory (DFT) calculation can also support the analytical and experimental results. Then, the complete and in-situ ionization of Li can be achieved by the further oxidization of SO₄^•- radicals from LFP powders. This work provides a novel strategy towards efficient and in-situ recycling of valuable metals from spent LIBs with minimized environmental footprint.

A mechanochemical method for one-step leaching of metals from spent LIBs

A one-step system based on mechanochemical activation and the use of grape skins (GS) was proposed to recover metals from lithium-ion batteries (LIBs) cathode waste. The effects of the ball-milling (BM) speed, BM time, and quantity of added GS on the metal leaching rate were explored. The spent lithium cobalt oxide (LCO) and its leaching residue before and after mechanochemistry were characterized by SEM, BET, PSD, XRD, FT-IR, and XPS analysis. Our study shows that mechanochemistry promotes the leaching efficiency of metals from LIBs battery cathode waste by changing the cathode material properties (that is, reducing the LCO particle size (12.126 μm ∼ 0.0928 μm), increasing the specific surface area (0.123 m²/g ∼ 15.957 m²/g), enhancing the hydrophilicity and surface free energy (57.44 mN/m² ∼ 66.18 mN/m²), promoting the generation of mesoporous structures, refining grains, disrupting the crystal structure, and increasing the microscopic strain, while deflecting the binding energy of the metal ions). A green, efficient and environmentally friendly process for the harmless and resource-friendly treatment of spent LIBs has been developed in this study.

Regeneration and usage of commercial activated carbon from the waste electrodes for the application of supercapacitors

Currently, efficient and cost-effective recycling of waste capacitors is a pressing issue. In this study, the recovery of electrode powder from waste supercapacitors and enabling the reuse of the prepared samples are reported. The recovered powder is directly activated by mixing it with KOH using chemical activation to regenerate the waste-activated carbon. The regenerated activated carbon's specific surface area could be restored to a level similar to that of the original commercial powder, reaching 1803.15 m²/g. The regenerated activated carbon has a high proportion of microporous, which played a crucial role in its electrochemical performance. The samples' capacity in the organic system reached 125.96 F/g at 0.2 A/g and 111.77 F/g at 20 A/g, with a retention rate of 88.74%. Furthermore, the capacitance was maintained at 91.18% after 10,000 cycles, showing good cycling performance. Additionally, the supercapacitor assembled from the regenerated activated carbon delivered a high energy density of 31.83 Wh/kg and a power density of 269.76 W/kg, indicating great application potential. Overall, this study offers a useful and low-cost approach for recycling activated carbon from waste electrodes, which would be possible for supercapacitors recycling.

Development of a novel chelation-based recycling strategy for the efficient decontamination of hazardous petroleum refinery spent catalysts

The conventional hydrometallurgical methods for recycling refinery spent hydroprocessing catalysts are ineffective in simultaneously removing all metals (Ni, V, and Mo) in a single-stage operation. In this study, a novel octadentate chelating agent, diethylenetriaminepentaacetic acid (DTPA-C₁₄H₂₃N₃O₁₀), has been proposed for the first time to remove toxic metals (Ni, V, and Mo) in a single stage of operation from an industrial spent atmospheric residue desulfurization (ARDS) catalysts. It was discovered that the efficient formation of metal-DTPA complexes was attained under the optimum experimental conditions (60 °C, stirring - 150 rpm, S/L ration (w/v) of 2.5%, 7.5% DTPA, and medium pH-9) that resulted in the high removal of Mo (83.6%), V (81.3%) and Ni (64.1%) from the spent ARDS catalyst. Kinetic studies suggest that the leaching process followed a semi-empirical Avrami equation (R² > 0.92), which predicted that the diffusion control reaction controlled the leaching. Species distribution and ecological risk analysis of the remaining metals in the insoluble residue (mostly Al₂O₃) indicated that the potential bioavailability of the remaining metals (except Ni) was significantly decreased, and residue poses a low ecological and contamination risk (individual contamination factor <1). Furthermore, the textural properties of the residue (BET surface area-103 m²/g and pore volume- 0.49 ml/g) were dramatically improved, suggesting that fresh hydroprocessing catalyst support can be synthesized using the leached residue. Compared to the conventional processes, the proposed chelating process is highly selective, closed-loop, and achieved high metal recovery in a single-stage operation while decreasing the environmental risks of the hazardous spent catalysts.

A closed-circuit cycle process for recovery of carbon and valuable components from spent carbon cathode by hydrothermal acid-leaching method

Spent carbon cathode (SCC) as a hazardous solid waste produced in aluminum electrolysis industry, contains plenty valuable components but generate a seriously threat to the environment. This paper focus on a closed-circuit cycle process for direct treatment of SCC based on the hydrothermal acid-leaching method. Thermodynamic calculation, single factor experiment, orthogonal experiment and kinetic study are utilized to obtain the leaching properties of impurities, optimize the leaching conditions, study the influence of conditions on leaching, and capture the restriction factors of leaching. The results indicate that the carbon content of the treated SCC can reach 97.3% when the leaching condition attach the optimal (liquid-solid ratio of 25 mL/g, temperature of 413 K, time of 270 min and acid concentration of 4 mol/L), and liquid-solid ratio is regarded as the crucial factor influencing on that. In addition, the activation energy of impurities reaches 6.25 kJ/mol and the whole leaching process is controlled by the diffusion extent. Finally, the filtrate after the hydrothermal acid leaching is treated, and calcium fluoride, cryolite and sodium chloride are successfully separated. The proposed process eliminates the harm of SCC to the environment, and completes a closed-circuit cycle for the treatment of SCC and recovery of valuable components. It enriches the hydrometallurgical processes of SCC, and provides an attractive scheme for the treatment of SCC.

Recovery of Valuable Metals from Cathode—Anode Mixed Materials of Spent Lithium-Ion Batteries Using Organic Acids

Spent lithium-ion batteries (LIBs) contain a large number of valuable metals and will be an important strategic resource in the future. Therefore, recycling is extremely important. In this work, acetic acid and hydrogen peroxide were used as leaching agents to recover valuable metals (lithium, cobalt, nickel, manganese, and aluminum) from cathode and anode materials (LiCoO2, LiAl0.2Co0.8O2, and C) of spent LIBs. The leaching solution and leaching residue were analyzed by inductive plasma optical emission spectrometry (ICP-OES), scanning electron microscopy (SEM), and X-ray diffraction (XRD). The optimum experimental conditions were obtained by changing the concentration of acetic acid, solid–liquid ratio, reaction temperature, time, and the concentration of hydrogen peroxide reducing agent. Under the experimental conditions of 2 M acetic acid, 4.0 vol.% H2O2, 20 g/L, and 70 °C for 40 min, the leaching rates of lithium, cobalt, nickel, manganese, and aluminum reached 98.56%, 94.61%, 96.39%, 97.97%, and 94.7%, respectively. This hydrometallurgical process is simple and environmentally friendly and maximizes the recovery of valuable metals from spent LIBs.

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.

Influence of cell opening methods on organic solvent removal during pretreatment in lithium-ion battery recycling

The use and development of lithium-ion batteries (LIBs) are promoting the technological transformation of individual mobility, consumer electronics and electric energy storage. At their end of life, the complex compounds are disposed by different recycling technologies with defined secondary raw material production. The applied depollution temperatures of the process routes influence not only the recycling efficiency but also the process expenditure, design, medium and costs. Different pretreatment strategies in terms of dismantling depth and depollution temperature are existing. Furthermore, manual and mechanical methods for cell opening are distinguished, which together with the depollution leads to a respective organic solvent evaporation. In this contribution to LIB recycling, the influence of different dismantling depths, achieved by manual cell opening, on the thermal depollution of the LIB cells regarding the mass difference originating by organic solvent evaporation are quantified, in order to determine cell and equipment properties for a safe cell opening. As a result, combinations of thermal depollution and manual cell opening are discussed regarding technical and economic feasibility. The process medium and equipment properties for a safe cell opening are determined. Furthermore, recommendations for future industrial LIB waste management are presented.

Assessment of recycling methods and processes for lithium-ion batteries

This review discusses physical, chemical, and direct lithium-ion battery recycling methods to have an outlook on future recovery routes. Physical and chemical processes are employed to treat cathode active materials which are the greatest cost contributor in the production of lithium batteries. Direct recycling processes maintain the original chemical structure and process value of battery materials by recovering and reusing them directly. Mechanical separation is essential to liberate cathode materials that are concentrated in the finer size region. However, currently, the cathode active materials are being concentrated at a cut point that is considerably greater than the actual size found in spent batteries. Effective physical methods reduce the cost of subsequent chemical treatment and thereafter re-lithiation successfully reintroduces lithium into spent cathodes. Some of the current challenges are the difficulty in controlling impurities in recovered products and ensuring that the entire recycling process is more sustainable.

Recycling of cathode material from spent lithium-ion batteries: Challenges and future perspectives

The intrinsic advancement of lithium-ion batteries (LIBs) for application in electric vehicles (EVs), portable electronic devices, and energy-storage devices has led to an increase in the number of spent LIBs. Spent LIBs contain hazardous metals (such as Li, Co, Ni, and Mn), toxic and corrosive electrolytes, metal casting, and polymer binders that pose a serious threat to the environment and human health. Additionally, spent LIBs may serve as an economic source for transition metals, which could be applied to redesigning under a closed-circuit recycling process. Thus, the development of environmentally benign, low cost, and efficient processes for recycling of LIBs for a sustainable future has attracted worldwide attention. Therefore, herein, we introduce the concept of LIBs and review state-of-art technologies for metal recycling processes. Moreover, we emphasize on LIB pretreatment approaches, metal extraction, and pyrometallurgical, hydrometallurgical, and biometallurgical approaches. Direct recycling technologies combined with the profitable and sustainable cathode healing technology have significant potential for the recycling of LIBs without decomposition into substituent elements or precipitation; hence, these technologies can be industrially adopted for EV batteries. Finally, commercial technological developments, existing challenges, and suggestions are presented for the development of effective, environmentally friendly recycling technology for the future.

Lithium Harvesting from the Most Abundant Primary and Secondary Sources: A Comparative Study on Conventional and Membrane Technologies

The exponential rise in lithium demand over the last decade, as one of the largest sources for energy storage in terms of lithium-ion batteries (LIBs), has posed a great threat to the existing lithium supply and demand balance. The current methodologies available for lithium extraction, separation and recovery, both from primary (brines/seawater) and secondary (LIBs) sources, suffer not only at the hands of excessive use of chemicals but complicated, time-consuming and environmentally detrimental design procedures. Researchers across the world are working to review and update the available technologies for lithium harvesting in terms of their economic and feasibility analysis. Following its excessive consumption of sustainable energy resources, its demand has risen sharply and therefore requires urgent attention. In this paper, different available methodologies for lithium extraction and recycling from the most abundant primary and secondary lithium resources have been reviewed and compared. This review also includes the prospects of using membrane technology as a promising replacement for conventional methods.

Optimization of Synergistic Leaching of Valuable Metals from Spent Lithium-Ion Batteries by the Sulfuric Acid-Malonic Acid System Using Response Surface Methodology

A new environmentally friendly and economical recycling process for extracting metals from spent lithium-ion batteries (LIBs) using sulfuric acid and malonic acid as leaching agents is proposed. By applying Box-Behnken design (BBD) and response surface methodology (RSM) optimization techniques, the global optimal solution of the maximum leaching rate of metals in spent LIBs is realized. The results show that under the optimal conditions of 0.93 M H₂SO₄, 0.85 M malonic acid, and a liquid/solid ratio of 61 g·L^-1, a temperature of 70 °C and 5 vol % of 30% H₂O₂, 99.79% Li, 99.46% Ni, 97.24% Co, and 96.88% Mn are recovered within 81 min. The error between the theoretical value and the actual value of the metal leaching rate predicted by the regression model is less than 1.0%. Additionally, the study of leaching kinetics reveals that the leaching process of Li, Ni, Co, and Mn in spent cathode materials was affected by the synergistic effect of interfacial mass transfer and solid product layer diffusion. Economic analysis reveals that evaluation index should be fully considered when formulating recovery processes for different metals. This process can reduce the environmental risks of heavy metal disposal and allow the reuse of metals recovered from spent LIBs.

Acid leaching of LiCoO2 enhanced by reducing agent. Model formulation and validation

In this work, a model has been formulated to describe the complex process of LiCoO₂ leaching through the participation of competing reactions in acid media including the effect of H₂O₂ as reducing agent. The model presented here describes the extraction of Li and Co in the presence and absence of H₂O₂, and it takes into account the different phenomena affecting the controlling mechanisms. In this context, the model predicts the swift from kinetic control to diffusion control. The model has been implemented and solved to simulate the leaching process. To validate the model and to estimate the model parameters, a set of 12 (in triplicate) extraction experiments were carried out varying the concentration of hydrochloric acid (within the range of 0.5-2.5 M) and hydrogen peroxide (range 0-0.6%v/v). The simulation results match fairly well with the experimental data for a wide range of conditions. Furthermore, the model can be used to predict results with different solid-liquid ratios as well as different acid and oxygen peroxide concentrations. This model could be used to design or optimize a LiCoO₂ extraction process facilitating the corresponding economical balance of the treatment.

Leaching kinetics and interface reaction of LiNi0.6Co0.2Mn0.2O2 materials from spent LIBs using GKB as reductant

The application of green reductant is signification to recycling of cathode materials from spent lithium ions batteries. Here, ginkgo biloba was developed for enhancing leaching of spent LiNi_0.6Co_0.2Mn_0.2O₂ materials with systematically analysis of leaching kinetics and interface reaction. The leaching efficiencies of Ni, Mn, Co, and Li reach respectively 98.65 %, 98.25 %, 98.41 % and 99.99 % under optimal condition of 1.8 mol/L H₂SO₄ concentration, 9 g/L ginkgo biloba, 80 °C leaching temperature, 40 min time and 15 g/L pulp density. The apparent activation energies for leaching of Ni, Co, Mn and Li determined as 74.63, 79.33, 73.14 and 23.43 kJ/mol, respectively, indicates that the leaching process was controlled by the surface chemical reaction during the leaching process. Meanwhile, the regenerated material with better electrochemical performance was obtained by co-precipitation and calcination from leachate. Finally, the process is environmental friendly and economical feasible for recycling of spent lithium-ion batteries.

Environmentally friendly automated line for recovering aluminium and lithium iron phosphate components of spent lithium-iron phosphate batteries

Lithium iron phosphate (LFP) batteries contain metals, toxic electrolytes, organic chemicals and plastics that can lead to serious safety and environmental problems when they are improperly disposed of. The published literature on recovering spent LFP batteries mainly focuses on policy-making and conceptual design. The production line of recovering spent LFP batteries and its detailed operation are rarely reported. A set of automatic line without negative impact to the environment for recycling spent LFP batteries at industrial scale was investigated in this study. It includes crushing, pneumatic separation, sieving, and poison gas treatment processes. The optimum retaining time of materials in the crusher is 3 minutes. The release rate is the highest when the load of the impact crusher is 800 g. An air current separator (ACS) was designed to separate LFP from aluminium (Al) foil and LFP powder mixture. Movement behaviour of LFP powder and Al foil in the ACS were analysed, and the optimized operation parameter (35.46 m/s) of air current speed was obtained through theoretical analysis and experiments. The weight contents of an Al foil powder collector from vibrating screen-3 and LFP powder collector from bag-type dust collector are approximately 38.7% and 52.4%, respectively. The economic cost of full manual dismantling is higher than the recovery production line. This recycling system provides a feasible method for recycling spent LFP batteries.

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.

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.

Management status of waste lithium-ion batteries in China and a complete closed-circuit recycling process

Lithium-ion batteries (LIBs) were used extensively in people's lives, especially with the vigorous promotion of new energy vehicles, which led to the generation of a large number of waste LIBs. In consideration of the enormous quantity, environmental risk, and resource properties, many countries have issued a series of laws and regulations to manage waste LIBs and developed a lot of recycling technologies. As the biggest producer of batteries in the world, China has also taken necessary measures to deal with this situation. This paper presents the latest regulations of waste LIBs in China and reviews the recycling strategies of waste LIBs, especially physical recycling methods. Based on the analysis of the current management status of waste LIBs in China and the recycling technologies, some management suggestions, and a complete closed-circuit recycling process including cascade utilization and resource recovery were put forward. A rough economic evaluation of the process was also conducted to demonstrate the economic feasibility of the proposed process. The purpose of this paper is to provide some valuable references for decision-making bodies in the improvement of waste lithium-ion battery management and to provide an environmentally friendly and industrial feasible recycling process for reference.

Hydrometallurgical Extraction of Li and Co from LiCoO2 Particles–Experimental and Modeling

The use of lithium-ion batteries as energy storage in portable electronics and electric vehicles is increasing rapidly, which involves the consequent increase of battery waste. Hence, the development of reusing and recycling techniques is important to minimize the environmental impact of these residues and favor the circular economy goal. This paper presents experimental and modeling results for the hydrometallurgical treatment for recycling LiCoO2 cathodes from lithium-ion batteries. Previous experimental results for hydrometallurgical extraction showed that acidic leaching of LiCoO2 particles produced a non-stoichiometric extraction of lithium and cobalt. Furthermore, the maximum lithium extraction obtained experimentally seemed to be limited, reaching values of approximately 65–70%. In this paper, a physicochemical model is presented aiming to increase the understanding of the leaching process and the aforementioned limitations. The model describes the heterogeneous solid–liquid extraction mechanism and kinetics of LiCoO2 particles under a weakly reducing environment. The model presented here sets the basis for a more general theoretical framework that would describe the process under different acidic and reducing conditions. The model is validated with two sets of experiments at different conditions of acid concentration (0.1 and 2.5 M HCl) and solid to liquid ratio (5 and 50 g L−1). The COMSOL Multiphysics program was used to adjust the parameters in the kinetic model with the experimental results.

Glucose oxidase-based biocatalytic acid-leaching process for recovering valuable metals from spent lithium-ion batteries

An environmentally benign leaching process for recovering valuable metals from the cathodes of spent lithium-ion batteries was developed. Glucose oxidase produced by Aspergillus niger can oxidize glucose to give the leaching agent gluconic acid. The presence of gluconic acid was proven by mass spectrometry. The cathode material morphology was characterized by X-ray diffractometry and scanning electron microscopy, and the efficiencies with which valuable metals were leached from the Li(Ni_xCo_yMn_z)O₂ material were determined by inductively coupled plasma optical emission spectroscopy. More than 95% of the Co, Li, Mn, and Ni were leached from spent lithium-ion batteries using a solid/liquid ratio of 30 g/L, 1 M gluconic acid leaching solution, a 1 vol% H₂O₂ reductant solution, a temperature of 70 °C, and a reaction time of 80 min. The leaching kinetics were perfectly described by the Avrami equation. The apparent activation energies for leaching of Li, Ni, Co, and Mn were determined as 41.76, 42.84, 43.59, and 45.35 kJ/mol, respectively, indicating that the surface chemical reaction is the rate-controlling step during this leaching process. This mild biocatalysis-aided acid leaching process is a promising method for effectively recovering valuable metals from spent lithium-ion batteries.

High-Performance Recovery of Cobalt and Nickel from the Cathode Materials of NMC Type Li-Ion Battery by Complexation-Assisted Solvent Extraction

The annual global volume of waste lithium-ion batteries (LIBs) has been increasing over years. Although solvent extraction method seems well developed, the separation factor between cobalt and nickel is still relatively low—only 72 when applying conventional continuous-countercurrent extraction. In this study, we improved the separation factor of cobalt and nickel by complexation-assisted solvent extraction. Before solvent extraction procedure, leaching kinetic of Li, Ni, Co and Mn was studied and can be explained by the Avrami equation. Leached residues were also investigated by SEM and XRD. Operation parameters of complexation-assisted solvent extraction were examined, including volume ratio of extractant to diluent, types of diluent, type of complexing reagent, extractant saponification percentage and volume ratio of organic phase to aqueous phase. The optimal separation factor of complexation-assisted solvent extraction could be improved to 372, which is five times that of conventional solvent extraction. The separation tendency would be interpreted by the relationship between extraction equilibrium pH and log distribution coefficient.

Gradient and facile extraction of valuable metals from spent lithium ion batteries for new cathode materials re-fabrication

Sustainable recycling value-added metals from spent lithium-ion batteries (LIBs) has been supposed to be a promising alternative to alleviate the current environmental and resource issues. Reduced reagents consumption and closed-loop reutilization are still challenging in current prevailing recycling processes. This study proposed a novel recycling strategy involved with gradient extraction of valuable metals and closed-loop re-fabrication of cathode materials. Lithium was selectively recovered as lithium enriched lixivium in mild tartaric acidic medium with a high yield of 99.7 % and little co-extraction of transition metals (Ni, Co and Mn) under optimized leaching conditions. Then transition metals enriched residues can be completely dissolved in facile sulfuric acidic medium without the contamination of Li. Li₂CO₃ and ternary precursors were recovered from Li enriched lixivium and transition metal enriched lixivium, respectively. Finally, cathode materials of LiNi_1/3Co_1/3Mn_1/3O₂ are refabricated using obtained products to close the recycling loop. It can be concluded that it is possible for the gradient recycling of Li and transition metals based on their inherent properties with minimized consumption of acids under facile leaching conditions, which can also facilitate metals separation process for closed-looped re-fabrication of new cathode materials.

De-agglomeration of cathode composites for direct recycling of Li-ion batteries

Direct recycling of Li-ion batteries (LIBs) reclaims electrode materials using physical separation followed by materials' rejuvenation processes. The cathode composites in LIBs contain both carbon black and PVDF binders in its chemistry. For the rejuvenation process to work, an ability to remove these impurities is desirable. In the present work, de-agglomeration of individual components from the cathode composites has been carried out using a mechanical process that is developed for preserving functional integrity of the cathode active materials. It has been shown that the size of the cathode composites is effectively reduced upon a de-agglomeration process due to a liberation of PVDF binders from the cathode composites. The de-agglomeration performance has been evaluated by separating mixed materials by the degree in surface hydrophobicity using the froth flotation method. The performance improves with end-of-life (EOL) LIBs compared to new LIBs, benefiting from a degradation of PVDF binders after charging-discharging cycles. X-ray photoelectron spectra suggests that the de-agglomeration is done by breaking intermolecular bond between PVDF and cathode active materials as well as covalent bond within PVDF binders. The present work demonstrates a non-chemical method for liberating individual components from cathode composites for the direct recycling of LIBs.

Recycling of cathode material from spent lithium ion batteries using an ultrasound-assisted DL-malic acid leaching system

Herein, a novel process involving ultrasound-assisted leaching developed for recovering Ni, Li, Co, and Mn from spent lithium-ion batteries (LIBs) is reported. Carbonate coprecipitation was utilized to regenerate LiNi_0.6Co_0.2Mn_0.2O₂ from the leachate. Spent cathode materials were leached in DL-malic acid and hydrogen peroxide (H₂O₂). The leaching efficiency was investigated by determining the contents of metal elements such as Li, Ni, Co, and Mn in the leachate using atomic absorption spectrometry (AAS). The filter residue and the spent cathode materials were examined using Fourier transform infrared (FTIR) and scanning electronic microscopy. The leaching efficiencies were 97.8% for Ni, 97.6% for Co, 97.3% for Mn, and 98% for Li under the optimized conditions (90 W ultrasound power, 1.0 mol/L DL-malic acid, 5 g/L pulp density, 80 °C, 4 vol% H₂O₂, and 30 min). The leaching kinetics of the cathode in DL-malic acid are in accordance with the log rate law model. The electrochemical analysis indicates that the LiNi_0.6Co_0.2Mn_0.2O₂ regenerated at pH 8.5 has good electrochemical performance. The specific capacity of the first discharge at 0.1 C is 168.32 mA h g^-1 at 1 C after 50 cycles with a capacity retention of 85.0%. A novel closed-loop process to recycle spent cathode materials was developed, and it has potential value for practical application and for contributing to resource recycling and environmental protection.

Reduction-ammoniacal leaching to recycle lithium, cobalt, and nickel from spent lithium-ion batteries with a hydrothermal method: Effect of reductants and ammonium salts

Some inevitable issues of the acid leaching method used to recycle spent lithium-ion batteries (LIBs), such as toxic gas emission, excessive acid-base consumption, inferior metal selectivity and equipment corrosion, have gradually emerged and restricted the promotion and development of this method. It is therefore essential to develop a sustainable closed-loop recycling technology (reduction-ammoniacal method) for spent LIBs. In this study, the effects of various species of ammonia, ammonium salts and reductants on the leaching of Li, Co, Ni, Mn and Al from spent LIBs were investigated with a hydrothermal method. An increase of the electrode potential of the reductant greatly accelerated the selective leaching of Li, Co and Ni, which agreed with the thermodynamic analysis results. The standard electrode potentials of the LiNi_xCo_yMn_1-x-yO₂ (NCM) materials were also determined by using approximate calculations. When using (NH₄)₂SO₃ as a reductant in a one-step leaching process, 100% Co, 98.3% Ni and 90.3% Li were extracted into the ammonia-ammonium chloride solutions. From the kinetics analysis, the surface chemical reaction shrinking core model was found to control the leaching behavior of Li, Co, and Ni in the reduction-ammoniacal leaching process. A shell-core structure was composed of a product layer, a diffusion layer of the solid core and an unreacted core. Species in the product layer reduced the leaching efficiencies of Li, Co, and Ni. The results obtained for this hydrothermal reduction-ammoniacal method applied to recycle spent LIBs provide insights for the design of a high-speed, exceptionally selective, closed-loop recycling technique.

Challenges to Future Development of Spent Lithium Ion Batteries Recovery from Environmental and Technological Perspectives

Spent lithium ion battery (LIB) recovery is becoming quite urgent for environmental protection and social needs due to the rapid progress in LIB industries. However, recycling technologies cannot keep up with the exaltation of the LIB market. Technological improvement of processing spent batteries is necessary for industrial application. In this paper, spent LIB recovery processes are classified into three steps for discussion: gathering electrode materials, separating metal elements, and recycling separated metals. Detailed discussion and analysis are conducted in every step to provide beneficial advice for environmental protection and technology improvement of spent LIB recovery. Besides, the practical industrial recycling processes are introduced according to their advantages and disadvantages. And some recommendations are provided for existing problems. Based on current recycling technologies, the challenges for spent LIB recovery are summarized and discussed from technological and environmental perspectives. Furthermore, great effort should be made to promote the development of spent LIB recovery in future research as follows: (1) gathering high-purity electrode materials by mechanical pretreatment; (2) green metals leaching from electrode materials; (3) targeted extraction of metals from electrode materials.

Maleic, glycolic and acetoacetic acids-leaching for recovery of valuable metals from spent lithium-ion batteries: leaching parameters, thermodynamics and kinetics

Environmentally friendly acid-leaching processes with three organic acids (maleic, glycolic and acetoacetic) were developed to recover valuable metals from the cathodic material of spent lithium-ion batteries (LiCoO₂). The leaching efficiencies of Li and Co by the maleic acid were 99.58% and 98.77%, respectively. The leaching efficiencies of Li and Co by the glycolic acid were 98.54% and 97.83%, while those by the acetoacetic acid were 98.62% and 97.99%, respectively. The optimal acid concentration for the maleic acid-, glycolic acid- and acetoacetic acid-leaching processes were 1, 2 and 1.5 mol l^-1, respectively, while their optimal H₂O₂ concentrations were 1.5, 2 and 1.5 vol%, respectively. The optimal solid/liquid ratio, temperature and reaction time for the leaching process of the three organic acids was the same (10 g l^-1, 70°C, 60 min). The thermodynamic formation energy of the leaching products and the Gibbs free energy of the leaching reactions were calculated, and the kinetic study showed that the leaching processes fit well with the shrinking-core model. Based on the comparison in the leaching parameters, the efficacy and availability of the three acids is as follows: maleic acid > acetoacetic acid > glycolic acid.

Upcycling of Spent Lithium Cobalt Oxide Cathodes from Discarded Lithium-Ion Batteries as Solid Lubricant Additive

This work provides an alternative solution to the challenge of battery recycling via the upcycling of spent lithium cobalt oxide (LCO) as a new promising solid lubricant additive. An advanced solid lubricant mixture of graphene, Aremco binder, and recycled LCO was formulated into a spray with the use of excess volatile organic solvent. Numerous flat steel disks were spray-coated with the new lubricant formulation and naturally dried followed by curing at 180 °C. When tested on a ball-on-disk up to 230 m in distance, the composite new solid lubricant reduced the coefficient of friction (COF) by 85% between two steel surfaces compared to unlubricated surfaces under a constant 1 GPa Hertzian pressure in an ambient environment. The tribofilm composition, particle size, and type of contact are identified as important parameters in the improvement of the COF. Scanning electron microscopy was used to study its morphology, and energy dispersive X-ray spectroscopy was used to analyze the composition of pristine and tested tribofilms. Upcycled spent low value LCO powder was used as a lubricant additive in tribology for the first time with exceptional lubricious properties.

Enhancement in leaching process of lithium and cobalt from spent lithium-ion batteries using benzenesulfonic acid system

Recycling of valuable metals from spent lithium ion batteries (LIBs) is of great significance considering the conservation of metal resources and the alleviation of potential hazardous effects on environment. Thus, the present work focuses on enhancing the efficiency of leaching process for the recovery of cobalt and lithium from the cathode active materials of spent LIBs. In this study, benzenesulfonic acid (C₆H₅SO₃H) with a reducing agent hydrogen peroxide (H₂O₂) was innovatively used as leaching reagents, and the operating variables were optimized to obtain higher leaching efficiencies. Results show the optimized leaching recovery of 99.58% Li and 96.53% Co was obtained under the conditions of 0.75 M benzenesulfonic acid, 3 vol% H₂O₂, a solid to liquid (S/L) ratio of 15 g/L, 500 rpm stirring speed, and 80 min leaching time at 90 °C. Moreover, a new kinetic model was introduced to describe the leaching kinetics of LiCoO₂ from the cathode material. The apparent activation energies E_a for leaching of lithium and cobalt are 41.06 and 35.21 kJ/mol, respectively, indicating that the surface chemical reaction is the rate-controlling step during this leaching process. Further, the proposed recovery mechanism for spent cathode material was raised by analyzing the experimental results and characterizing the morphological and chemical state (i.e. SEM-EDS, XPS and XRD) of raw material and leaching residues. In comparison with the previous leaching process, this research was found to be efficient, low energy consumption, and environmental friendly.