A promising physical method for recovery of LiCoO 2 and graphite from spent lithium-ion batteries: Grinding flotation

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.

Influences of plasma treatment parameters on the hydrophobicity of cathode and anode materials from spent lithium-ion batteries

The recycling of spent lithium-ion batteries (LIBs) can not only reduce the potential harm caused by solid waste piles to the local environment but also provide raw materials for manufacturing new batteries. Flotation is an alternative approach to achieve the selective separation of cathode and anode active materials from spent LIBs. However, the presence of organic binder on the surface of hydrophilic lithium transition-metal oxides results in losses of cathode materials in the froth phase. In this study, plasma treatment was utilized to remove organic layers from cathode and anode active materials. Firstly, the correlations between plasma treatment parameters (e.g., input power, air flowrate, and treatment time) were explored and the contact angles of cathode and anode active materials were investigated by the response surface methodology. Secondly, differences in the flotation recoveries of cathode and anode active materials were enhanced with plasma modification prior to flotation, which is consistent with the contact angle measurement. Finally, the plasma-modification mechanisms of hydrophobicity of cathode and anode active materials were discussed according to Fourier Transform infrared spectroscopy (FTIR) and X-ray photoelectron spectroscopy (XPS) analyses. The proposed method could be a promising tool to enhance the flotation separation efficiency of cathode and anode active materials for the recycling of spent LIBs.

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.

Opportunity and challenges in recovering and functionalizing anode graphite from spent lithium-ion batteries: A review

Recent concerns have emerged regarding the improper disposal of spent lithium-ion batteries (LIBs), which has garnered widespread societal attention. Graphite materials accounted for 12-21 wt % of LIBs' mass, typically contain heavy metals, binders, and residual electrolytes. Regenerating spent graphite not only alleviated the shortage of plumbago, but also contributed to the supports environmental protection as well as national carbon peak and neutrality ("dual carbon" goals). Despite significant advancements in recycling spent LIBs had been made, a comprehensive overview of the processes for pretreatment, regeneration, and functionalization of spent graphite from retired LIBs, along with the associated technical standards and industry regulations enabling their smooth implementation still needed to be mentioned. Hence, we conducted the following research work. Firstly, the pre-treatment process of spent graphite, including discharging, crushing, and screening was summed up. Next,. Subsequently, graphite recovery methods, such as acid leaching, pyrometallurgy, and combined methods were summarized. Moreover, the modification and doping approach was used to enhance the electrochemical properties of graphite. Afterwards, we reviewed the functionalization of anode graphite from an economically and environmentally friendly view. Meanwhile, the technical standards and industry regulations of spent LIBs in domestic and oversea industries were described. Finally, we provided an overview of the technical challenges and development bottlenecks in graphite recycling, along with future prospects Overall, this study outlined the opportunities and challenges in recovering and functionalizing of anode materials via a efficient and sustainable processes.

Selective Recovery of Cathode Materials from Spent Lithium-Ion Battery Material with a Near-Room-Temperature Separation

Effective separation of cathode materials from the current collector is a critical step in recycling a spent lithium-ion battery (LIB). This typically necessitates the decomposition or dissolution of the organic binder, poly(vinylidene fluoride) (PVDF), to achieve efficient recovery of cathode materials. However, this process requires a high decomposition temperature, typically between 400 and 600 °C, and can lead to side reactions, such as current collector oxidation/brittleness, decomposition of cathode materials, and formation of metal fluorides. In this study, we propose that non-thermal plasma (NTP) treatment can be used to achieve an extremely high separation of cathode materials and aluminum current collector at near room temperature. Instead of relying on PVDF decomposition, which requires high temperatures, PVDF can be deactivated by partially breaking down long molecular chains with appropriate NTP conditions. With a total treatment time of around 2000 s and an environmental temperature of approximately 80 °C, minor side reactions can be avoided. The separation rate can reach up to 95.69%, and high-quality cathode materials can be obtained with only 0.02 wt % aluminum impurity content. This research could potentially offer a new approach toward minimizing recycling steps and reducing energy consumption in the recycling of spent LIBs. It could also be extended to the recovery of a broader range of electronic wastes.

The Foreseeable Future of Spent Lithium-Ion Batteries: Advanced Upcycling for Toxic Electrolyte, Cathode, and Anode from Environmental and Technological Perspectives

With the rise of the new energy vehicle industry represented by Tesla and BYD, the need for lithium-ion batteries (LIBs) grows rapidly. However, owing to the limited service life of LIBs, the large-scale retirement tide of LIBs has come. The recycling of spent LIBs has become an inevitable trend of resource recovery, environmental protection, and social demand. The low added value recovery of previous LIBs mostly used traditional metal extraction, which caused environmental damage and had high cost. Beyond metal extraction, the upcycling of spent LIBs came into being. In this work, we have outlined and particularly focus on sustainable upcycling technologies of toxic electrolyte, cathode, and anode from spent LIBs. For electrolyte, whether electrolyte extraction or decomposition, restoring the original electrolyte components or decomposing them into low-carbon energy conversion is the goal of electrolyte upcycling. Direct regeneration and preparation of advanced materials are the best strategies for cathodic upcycling with the advantages of cost and energy consumption, but challenges remain in industrial practice. The regeneration of advanced graphite-based materials and battery-grade graphite shows us the prospect of regeneration of anode. Furthermore, the challenges and future development of spent LIBs upcycling are summarized and discussed from technological and environmental perspectives.

High-performance expanded graphite regenerated from spent lithium-ion batteries by integrated oxidation and purification method

Currently, the recycling of spent lithium-ion batteries (LIBs) has mainly been focused on the extraction of precious metals, such as lithium, cobalt and nickel from cathodes, while the waste graphite anode has been overlooked due to its low-cost production and abundant resources reserve. However, there are enormous potential value and pollution risk in the view of graphite recycling. Thus, we propose an original method to prepare expanded graphite (EG) as new anode material generated from waste graphite in LIBs which integrates the oxidation and purification in one-step. By regulating the oxidizability of potassium hypermanganate in the sulfur-phosphorus mixed acid system, the expansion of graphite and removal of impurities are realized simultaneously and thoroughly. As anticipated, the shortening of preparation process and purification procedure can also reduce the generation of polluting substances and production cost. It displays excellent electrochemical performance (reversible capacity of 435.8 mAh·g-1 at 0.1C and long-term cycling property of 370 mAh·g-1 at 1C after 1000 cycles), which is even higher than that of pristine commercial graphite. This delicate strategy of high-performance expanded graphite recycling achieves the integration of purification and value-added processes, providing the instructive guide to regenerate industrial-grade anode materials for the increasing LIBs demand in the future.

Recycling Hazardous and Valuable Electrolyte in Spent Lithium-Ion Batteries: Urgency, Progress, Challenge, and Viable Approach

Recycling spent lithium-ion batteries (LIBs) is becoming a hot global issue due to the huge amount of scrap, hazardous, and valuable materials associated with end-of-life LIBs. The electrolyte, accounting for 10-15 wt % of spent LIBs, is the most hazardous substance involved in recycling spent LIBs. Meanwhile, the valuable components, especially Li-based salts, make recycling economically beneficial. However, studies of electrolyte recycling still account for only a small fraction of the number of spent LIB recycling papers. On the other hand, many more studies about electrolyte recycling have been published in Chinese but are not well-known worldwide due to the limitations of language. To build a bridge between Chinese and Western academic achievements on electrolyte treatments, this Review first illustrates the urgency and importance of electrolyte recycling and analyzes the reason for its neglect. Then, we introduce the principles and processes of the electrolyte collection methods including mechanical processing, distillation and freezing, solvent extraction, and supercritical carbon dioxide. We also discuss electrolyte separation and regeneration with an emphasis on methods for recovering lithium salts. We discuss the advantages, disadvantages, and challenges of recycling processes. Moreover, we propose five viable approaches for industrialized applications to efficiently recycle electrolytes that combine different processing steps, ranging from mechanical processing with heat distillation to mechanochemistry and in situ catalysis, and to discharging and supercritical carbon dioxide extraction. We conclude with a discussion of future directions for electrolyte recycling. This Review will contribute to electrolyte recycling more efficiently, environmentally friendly, and economically.

The Recycling of Spent Lithium-Ion Batteries: Crucial Flotation for the Separation of Cathode and Anode Materials

The recycling of spent lithium-ion batteries (LIBs) has attracted great attention, mainly because of its significant impact on resource recycling and environmental protection. Currently, the processes involved in recovering valuable metals from spent LIBs have shown remarkable progress, but little attention has been paid to the effective separation of spent cathode and anode materials. Significantly, it not only can reduce the difficulty in the subsequent processing of spent cathode materials, but also contribute to the recovery of graphite. Considering the difference in their chemical properties on the surface, flotation is an effective method to separate materials, owing to its low-cost and eco-friendly characteristics. In this paper, the chemical principles of flotation separation for spent cathodes and materials from spent LIBs is summarized first. Then, the research progress in flotation separation of various spent cathode materials (LiCoO₂, LiNi_xCo_yMn_zO₂, and LiFePO₄) and graphite is summarized. Given this, the work is expected to offer the significant reviews and insights about the flotation separation for high-value recycling of spent LIBs.

Challenges in Recycling Spent Lithium-Ion Batteries: Spotlight on Polyvinylidene Fluoride Removal

In the recycling of retired lithium-ion batteries (LIBs), the cathode materials containing valuable metals should be first separated from the current collector aluminum foil to decrease the difficulty and complexity in the subsequent metal extraction. However, strong the binding force of organic binder polyvinylidene fluoride (PVDF) prevents effective separation of cathode materials and Al foil, thus affecting metal recycling. This paper reviews the composition, property, function, and binding mechanism of PVDF, and elaborates on the separation technologies of cathode material and Al foil (e.g., physical separation, solid-phase thermochemistry, solution chemistry, and solvent chemistry) as well as the corresponding reaction behavior and transformation mechanisms of PVDF. Due to the characteristic variation of the reaction systems, the dissolution, swelling, melting, and degradation processes and mechanisms of PVDF exhibit considerable differences, posing new challenges to efficient recycling of spent LIBs worldwide. It is critical to separate cathode materials and Al foil and recycle PVDF to reduce environmental risks from the recovery of retired LIBs resources. Developing fluorine-free alternative materials and solid-state electrolytes is a potential way to mitigate PVDF pollution in the recycling of spent LIBs in the EV era.

Chemical-free pressure washing system as pretreatment to harvest cathode materials

Recycling cathode materials from spent lithium-ion batteries has the potential to reduce damages to the environment and human health due to hazardous waste treatment, and mitigate supply risks of raw materials. Related political incentives or regulations have led to increased research and development efforts on cathode recycling. Promising approaches include direct recycling and hydrometallurgical processes, where delamination is the first step after collection of cathodes. In this study, we examined a pressure washing system's ability to harvest cathode materials. A high-pressure water jet provides strong forces to overcome the adhesion provided by organic binders. Four factors (water pressure, distance between nozzle and cathode, incident angle of water jet, and nozzle type) were investigated using a 3^4-1 fractional factorial design to screen important parameters and find the optimal conditions. Compared with other delamination processes where chemical reagents and heating are involved, the chemical-free pressure washing system can achieve separation in a few seconds (∼74 min/m²) at room temperature, which remarkably improves the efficiency of delamination. The particle size of recycled products (D50 of 31.87 μm) is significantly reduced without Al contamination from current collectors or morphological damages. In addition, three types of recycled cathode materials were used as inputs for the acid leaching process. High leaching efficiencies of lithium (>90 %) and cobalt (>85 %) suggest that the pressure washing system could be a practical, economical, and eco-friendly pretreatment process to harvest cathode materials.

Recovery of carbon and cryolite from spent carbon anode slag of electrolytic aluminum by flotation based on the evaluation of selectivity index

One of the main electrolytic aluminum production costs is the consumption of carbon anodes, and carbon anode slag is a common hazardous waste in the aluminum industry. In this work, electrolytic aluminum carbon anode slag was separated by flotation. Using the selectivity index (SI) as an indicator, the influencing factors of the carbon slag flotation process were optimized, and the separation performance of carbon and cryolite in the carbon anode slag was investigated. The raw carbon anode slag was ground for 40 min to achieve dissociation of the cryolite from the carbon, the optimized SI value was then used to determine the optimal flotation test conditions. The test results showed that the SI value under the optimal grinding flotation was approximately four times larger than the value of direct flotation. This indicated that carbon anode slag had a better flotation selectivity under the grinding flotation, which significantly improved the flotation performance.

Advances and challenges in anode graphite recycling from spent lithium-ion batteries

Spent lithium-ion batteries (LIBs) have been one of the fast-growing and largest quantities of solid waste in the world. Spent graphite anode, accounting for 12-21 wt% of batteries, contains metals, binders, toxic, and flammable electrolytes. The efficient recovery of spent graphite is urgently needed for environmental protection and resource sustainability. Recently, more and more studies have been focused on spent graphite recycling, while the advance and challenges are rarely summarized. Hence, this study made a comprehensive review of graphite recycling including separation, regeneration, and synthesis of functional materials. Firstly, the pretreatment of graphite separation was overviewed. Then, the spent graphite regeneration methods such as leaching, pyrometallurgy, their integration processes, etc. were systematically introduced. Furthermore, the modification strategies to enhance the electrochemical performance were discussed. Subsequently, we reviewed in detail the synthesis of functional materials using spent graphite for energy and environmental applications including graphene, adsorbents, catalysts, capacitors, and graphite/polymer composites. Meanwhile, we briefly compared the economic and environmental benefits of graphite regeneration and other functional materials production. Finally, the technical bottlenecks and challenges for spent graphite recycling were summarized and some future research directions were proposed. This review contributes to spent LIBs recycling more efficiently and profitably in the future.

Regeneration and utilization of graphite from the spent lithium-ion batteries by modified low-temperature sulfuric acid roasting

Recycling spent graphite in spent lithium-ion batteries (LIBs) is crucial for lacking high-quality graphite and environmental protection. Here, an environmentally friendly and economical modified method based on sulfate roasting was proposed to recycle spent graphite via low temperature roasting at 250 °C with sodium fluoride as an assistant additive. Recycling leads to graphite with a high purity of 99.55 % and chemical structures for energy storage. Batteries manufactured in regenerated graphite deliver a high initial charge capacity of 333.9 mAh/g with an initial columbic efficiency of 85.71% and excellent capacity retention of 91.2% after 400 cycles. In addition, the waste produced in the method could be well treated, and by-products 177 g of sodium sulfate would be collected per 1 kg spent graphite and NaF, equivalent to 78.95% of the added amount obtained through wastewater and exhaust gas, respectively. The regenerated sodium fluoride will be re-applied to the recovery spent graphite. The loop-closed method shows great promise for the industrial-scale recycling of spent graphite for energy storage applications.

Application of Roasting Flotation Technology to Enrich Valuable Metals from Spent LiFePO4 Batteries

The application of lithium-ion batteries (LIBs) in electric vehicles has attracted wide attention in recent years, especially LiFePO₄ batteries that have been extensively used in large electric buses and cars. The increased demand for LIBs has greatly stimulated lithium-ion battery production, which subsequently has led to greatly increased quantities of spent LIBs. From the perspective of environmental protection and resource recovery, the recycling of spent LIBs is of great significance. In this study, the roasting flotation technology was applied to enrich valuable metals from the mixed electrode powder of spent LiFePO₄ batteries. Roasting could thoroughly remove the organic outer layer coated on the surface of electrode-active materials, which improved the flotation enrichment efficiency of valuable metals in the mixed electrode powder of spent LiFePO₄ batteries. Under the optimum conditions of roasting at 500 °C for 1 h, the enrichment efficiency of Li and Fe reached the best. The recovery and the enrichment ratio of Li were 95.87% and 1.37, respectively, while the recovery and the enrichment ratio of Fe were 95.25% and 1.36, respectively. Roasting flotation was an efficient process to enrich valuable metals from spent LiFePO₄ batteries without wasting graphite resources.

Obtaining and Characterization of Highly Crystalline Recycled Graphites from Different Types of Spent Batteries

Spent batteries recycling is an important way to obtain low-cost graphite. Nevertheless, the obtaining of crystalline graphite with a rather low density of defects is required for many applications. In the present work, high-quality graphites have been obtained from different kinds of spent batteries. Black masses from spent alkaline batteries (batteries black masses, BBM), and lithium-ion batteries from smartphones (smartphone black masses, SBM) and electric and/or hybrid vehicles (lithium-ion black masses, LBM) were used as starting materials. A hydrometallurgical process was then used to obtain recycled graphites by acidic leaching. Different leaching conditions were used depending on the type of the initial black mass. The final solids were characterized by a wide set of complementary techniques. The performance as Li ion batteries anode of the sample with better structural quality was assessed.

Microwave hydrothermal renovating and reassembling spent lithium cobalt oxide for lithium-ion battery

With the growing number of lithium-ion batteries (LIBs) that are consumed by worldwide people, recycling is necessary for addressing environmental problems and alleviating energy crisis. Especially, it is meaningful to regenerate LIBs from spent batteries. In this paper, the microwave hydrothermal method is used to replenish lithium, assemble particles and optimize the crystal structure of the spent lithium cobalt oxide. The microwave hydrothermal process can shorten the reaction time, improve the internal structure, and uniformize the particle size distribution of lithium cobalt oxide. It helps to construct a regenerated lithium cobalt oxide (LiCoO₂) battery with high-capacity and high-rate properties (141.7 mAh g^-1 at 5C). The cycle retention rate is 94.5% after 100 cycles, which is far exceeding the original lithium cobalt oxide (89.7%) and LiCoO₂ regenerated by normal hydrothermal method (88.3%). This work demonstrates the feasibility to get lithium cobalt oxide batteries with good structural stability from spent lithium cobalt oxide batteries.

Critical strategies for recycling process of graphite from spent lithium-ion batteries: A review

With the explosive growth of spent lithium-ion batteries (LIBs), the effective recycling of graphite as a key negative electrode material has become economically attractive and environmentally significant. This review reports the recent research progress in recycling strategies for spent graphite from the perspectives of separation and reuse. First, technologies for separating graphite powder after direct crushing and artificially splitting are introduced, and the shortcomings of cost control and separation efficiency are reported. Subsequently, the reuse of recycled spent graphite is systematically summarized in terms of regeneration into battery materials, low-value utilization, and high-value conversion. Special attention has been paid to different aging degrees of retired batteries, as well as the performance and applications of regenerated graphite. Finally, upcoming research efforts on evaluation the standard establishment, development of advanced technology, and potential value enhancement to meet practical the industrial conditions and facilitate industry installation are proposed.

Improving Separation Efficiency in End-of-Life Lithium-Ion Batteries Flotation Using Attrition Pre-Treatment

The comminution of spent lithium-ion batteries (LIBs) produces a powder containing the active cell components, commonly referred to as “black mass.” Recently, froth flotation has been proposed to treat the fine fraction of black mass (<100 µm) as a method to separate anodic graphite particles from cathodic lithium metal oxides (LMOs). So far, pyrolysis has been considered as an effective treatment to remove organic binders in the black mass in preparation for flotation separation. In this work, the flotation performance of a pyrolyzed black mass obtained from an industrial recycling plant was improved by adding a pre-treatment step consisting of mechanical attrition with and without kerosene addition. The LMO recovery in the underflow product increased from 70% to 85% and the graphite recovery remained similar, around 86% recovery in the overflow product. To understand the flotation behavior, the spent black mass from pyrolyzed LIBs was compared to a model black mass, comprising fully liberated LMOs and graphite particles. In addition, ultrafine hydrophilic particles were added to the flotation feed as an entrainment tracer, showing that the LMO recovery in overflow products is a combination of entrainment and true flotation mechanisms. This study highlights that adding kerosene during attrition enhances the emulsification of kerosene, simultaneously increasing its (partial) spread on the LMOs, graphite, and residual binder, with a subsequent reduction in selectivity.

Unveiling Sodium Ion Pollution in Spray-Dried Precursors and Its Implications for the Green Upcycling of Spent Lithium-Ion Batteries

Unclear impurity pollution is one of the key scientific problems that limit the large-scale production of new lithium-ion batteries (LIBs) from spent LIBs. This work is the first to report the pollution path, pollution degree, and solution method of sodium ions in the recycling process of spent LIBs in the real world. The results show that sodium ions can intrude into the precursor particles to form crystalline salts with the anion of the leaching acid that cover the transition metal elements, thereby resulting in a failed precursor. Specifically, the intrusion of sodium ions will produce a variety of pollutants containing metal oxide bonds, such as Na-O, NaO₂, and Na⁺-O₂, on the precursor surface. These active lattice oxygen will further adsorb or react to form organic oxygen, chemical oxygen, and free oxygen, which will highly deteriorate the surface cleanliness. Strictly controlling the consumption of sodium salt in each step and using ammonia instead of NaOH for pH regulation can effectively solve sodium ion pollution to prepare high-quality battery precursors. It reveals that for the green upcycling of spent LIBs, we should strengthen the design of the recycling process to reduce the consumption of chemical reagents, which will produce unexpected secondary pollution.

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.

Direct recovery of degraded LiCoO2 cathode material from spent lithium-ion batteries: Efficient impurity removal toward practical applications

Regenerating cathode material from spent lithium-ion batteries (LIBs) permits an effective approach to resolve resource shortage and environmental pollution in the increasing battery industry. Directly renovating the spent cathode materials is a promising way, but it is still challenging to efficiently remove all of the complex impurities (such as binder, carbon black, graphite and current collectors) without destroying the material structure in the electrode. Herein, a facile strategy to directly remove these impurities and simultaneously repair the degraded LiCoO₂ by a target healing method is reported. Specifically, by using an optimized molten salt system of LiOH-KOH (molar ratio of 3:7) where LiNO₃ and O₂ both serve as oxidants, the impurities can be completely removed, while the structure, composition and morphology of degraded LiCoO₂ can be successfully repaired to commercial level based on a two-stage heating process (300 °C for 8 h and 500 °C for 16 h, respectively), resulting in a high recovery rate of approximately 100% for cathode material. More importantly, the regenerated LiCoO₂ exhibits a high reversible capacity, good cycling stability and excellent rate capability, which are comparable with commercial LiCoO₂. This work demonstrates an efficient approach to recycle and reuse advanced energy materials.

Reuse of LiCoO2 Electrodes Collected from Spent Li-Ion Batteries after Electrochemical Re-Lithiation of the Electrode

The recycling of used Li-ion batteries is important as the consumption of batteries is increasing every year. However, the recycling of electrode materials is tedious and energy intensive with current methods, and part of the material is lost in the process. In this study, an alternative recycling method is presented to minimize the number of steps needed in the positive electrode recovery process. The electrochemical performance of aged and re-lithiated Mg-Ti-doped LiCoO2 and stoichiometric LiCoO2 was investigated and compared. The results showed that after re-lithiation the structure of original LiCoO2 was restored, the capacity of an aged LiCoO2 reverted close to the capacity of a fresh LiCoO2 , and the material could thus be recovered. The re-lithiated Mg-Ti-doped LiCoO2 provided rate capability properties only slightly declined from the rate capability of a fresh material and showed promising cyclability in half-cells.

A critical review of current technologies for the liberation of electrode materials from foils in the recycling process of spent lithium-ion batteries

Proper disposal of spent lithium-ion batteries is beneficial for the resource recycling and pollution elimination. Full liberation of electrode materials, including the liberation between electrode material and current collector (copper/aluminum foils) and the liberation among electrode material particles, is the pivotal precondition for improving the recovery efficiency of electrode materials. In this article, authors attempt to carry out a summary of current technologies used in the liberation of electrode materials derived from spent lithium-ion batteries. However, specialized studies about the liberation of electrode materials are insufficient at present. This research clearly shows that: (1) Organic binder must be removed so as to improve the liberation and metallurgy efficiency of electrode materials; (2) A collaboration of varied technologies is the necessary process to achieve high liberation efficiency between electrode materials and copper/aluminum foils; (3) Pyrolysis may be a recommended technology for removal of organic binder because part of pyrolysis products can be recovered. Finally, an alternative recycling flowchart of spent LIBs is proposed.

Synthesis of graphene and recovery of lithium from lithiated graphite of spent Li-ion battery

Recycling of spent Li-ion batteries is crucial for achieving sustainable development of battery industry. Current recycling processes mainly focus on valuable metals but less attention has been paid to spent graphite, which generally ends up as secondary waste. In this study, a process for preparing graphene and recovering Li in anode as a by-product from spent graphite was developed. The key point was to re-charge the spent LIBs to generate lithium graphite intercalation compounds. The lithium graphite intercalation compounds were then subjected to a hydrolysis procedure and graphene could be produced through ultrasonic treatment via the expansion/micro-explosion mechanism. Experimental results demonstrated that 1-4 layered graphene could be efficiently produced when spent Li-ion batteries with beyond 50% capacity were re-charged. The prepared graphene showed high quantity containing few defects (I_D/I_G = 0.33, C/O = 13.2 by energy dispersive spectroscopy and C/O = 8.8 by X-ray photoelectron spectroscopy). In addition, Li was simultaneously recovered in the form of battery-grade lithium carbonate in the above process. Economic analysis indicated that the graphene production cost was extremely low ($540/ton) compared to that of commercial graphene.

Recent advances in pretreating technology for recycling valuable metals from spent lithium-ion batteries

In recent years, the amount of spent lithium-ion batteries (LIBs) increase sharply due to the promotion of new energy vehicles and the limited service life. Recycling of spent LIBs has attracted much attention because of the serious environmental pollution and high economic value. Although some established techniques have been presented in spent LIBs recycling process, but most of them focus on cathode material recycling due to its high economic value. Therefore, preparation of high purity cathode material by a proper pretreating technology is an important procedure. In this paper, the technologies used in the pretreating process of spent LIBs are summarized systematically from three main points of discharging procedure, liberation, and separation. The collaborative application of multi-technologies is the key to realize efficient pretreating process, which can lay the foundation for the subsequent metallurgical process. In addition, an alternative pretreating flowchart of spent LIBs is proposed based on the multi-process collaboration. Pretreating procedures in this process are mainly based on the physical property difference, and they include "Discharging-Shredding-Crushing-Sieving-Separation".

High-value utilization of graphite electrodes in spent lithium-ion batteries: From 3D waste graphite to 2D graphene oxide

The graphite electrodes of spent lithium-ion batteries (LIBs) have a good crystalline composition and layered structure, and the recovery potential is promising. However, the internal and external surfaces of the waste graphite are often polluted with various organic and inorganic impurities, which seriously restrict its high-value utilization. Herein, the microstructure and surface analysis of waste graphite at variable scales were carried out systematically to reveal the types and occurrence status of impurities and their influence on the preparation of graphene oxide (GO) using a modified Hummers method. The results show that the graphite surface contaminants are polyvinylidene fluoride binder, LiPF₆ electrolyte and LiF residue from the solid electrolyte interface, while residual lithium (Li₂CO₃) and CuO were found to have invaded the crystal structure of graphite. Fortunately, the modified Hummers method can effectively remove these complicated associated impurities and prevent their re-contamination on the GO surface. More importantly, the modified Hummers method can not only destroy the longitudinal molecular bonds between graphite layers, but also splice them horizontally to form 2D GO, which is verified by high-resolution transmission electron microscope (HR-TEM) images. This paper provides theoretical support and practical guidance for the high-value utilization of waste graphite in spent LIBs.

Theoretical-molar Fe3+ recovering lithium from spent LiFePO4 batteries: an acid-free, efficient, and selective process

In spent lithium iron phosphate batteries, lithium has a considerable recovery value but its content is quite low, thus a low-cost and efficient recycling process has become a challenging research topic. In this paper, two methods about using the non-oxidizing inorganic iron salt - Fe₂(SO₄)₃ to recover lithium from LiFePO₄ are proposed. The method-1 is theoretical-molar Fe₂(SO₄)₃ (Fe₂(SO₄)₃ : LiFePO₄ =1:2) dosage is added and more than 97% of lithium can be leached in just 30 min even under a pretty high solid-liquid ratio of 500 g/L. Spectrophotometry provides the evidence of Fe²⁺/Fe³⁺ substitution in the leaching process. In the method-2, the generated Fe²⁺ originating from LiFePO₄ is fully utilized with the addition of H₂O₂, and the dosage of Fe₂(SO₄)₃ is decreased by two thirds (Fe₂(SO₄)₃ : LiFePO₄ =1:6). Several sulphates (CuSO₄, NiSO₄, MgSO₄) are employed to explore the leaching mechanism. All the results reveal that the reaction of Fe³⁺ substituting Fe²⁺ has a powerful driving force. In addition, these two leaching processes simultaneously present superior selectivity for the impurities. The Fe₂(SO₄)₃ in two methods does not cause pollution and is easily regenerated by adding H₂SO₄. The proposed rapid, efficient and selective leaching thought would be a competitive candidate for recycling spent LiFePO₄ batteries.

Organics removal combined with in situ thermal-reduction for enhancing the liberation and metallurgy efficiency of LiCoO2 derived from spent lithium-ion batteries

Liberation and reduction of cathode material are the necessary procedures for improving the recycling efficiency of cathode material derived from spent lithium-ion batteries. In this research work, a pyrolysis technology was utilized to remove the organic binder and enhance liberation of electrode materials. At the same time, pyrolysis treatment can facilitate the thermal-reduction of Co³⁺ in LiCoO₂ to Co²⁺ with surface organics, which lays a foundation for the subsequent reductant-free acid leaching. Results indicate that the crystal structure of pure LiCoO₂ is not changed at a pyrolysis temperature of 600 °C, but LiCoO₂ transforms to CoO, Li₂CO₃, LiF, and Li₂O under the reduction action of HF, pyrolytic carbon, and additive carbon black. Water-impact crushing is synchronized with water-leaching to separate electrode materials from aluminum foil and recover Li element. Afterwards, reductant-free acid leaching technology can be utilized to recycle Li and Co from spent LiCoO₂ batteries. Recovery efficiency of Li element in water-leaching process was up to 92.17% while the remaining 7.83% of Li and all Co elements were recovered during reductant-free acid leaching process. Based on the foundation analysis, the green chemical process for recovering valuable metals from spent lithium-ion batteries was proposed.

Environment-friendly technology for recovering cathode materials from spent lithium iron phosphate batteries

The consumption of lithium iron phosphate (LFP)-type lithium-ion batteries (LIBs) is rising sharply with the increasing use of electric vehicles (EVs) worldwide. Hence, a large number of retired LFP batteries from EVs are generated annually. A recovery technology for spent LFP batteries is urgently required. Compared with pyrometallurgical, hydrometallurgical and biometallurgical recycling technologies, physical separating technology has not yet formed a systematic theory and efficient sorting technology. Strengthening the research and development of physical separating technology is an important issue for the efficient use of retired LFP batteries. In this study, spent LFP batteries were discharged in 5 wt% sodium chloride solution for approximately three hours. A specially designed machine was developed to dismantle spent LFP batteries. Extending heat treatment time exerted minimal effect on quality loss. Within the temperature range of 240°C-300°C, temperature change during heat treatment slightly affected mass loss. The change in heat treatment temperature also had negligible effect on the shedding quality of LFP materials. The cathode material and the aluminium foil current collector accounted for a certain proportion in a sieve with a particle size of -1.25 + 0.40 mm. Corona electrostatic separation was performed to separate the metallic particles (with a size range of -1.5 + 0.2 mm) from the nonmetallic particles of crushed spent LFP batteries. No additional reagent was used in the process, and no toxic gases, hazardous solid waste or wastewater were produced. This study provides a complete material recovery process for spent LFP batteries.

Lithium-ion batteries towards circular economy: A literature review of opportunities and issues of recycling treatments

Nowadays, Lithium-ion batteries are widely used in advanced technological devices and Electric and Hybrid Vehicles, due to their high energy density for weight, reduced memory effect and significant number of supported charging/discharging cycles. As a consequence, the production and the use of Lithium-ion batteries will continuously increase in the near future, focusing the global attention on their End-of-Life management. Unfortunately, wasted Lithium-ion batteries treatments are still under development, far from the optimization of recycling processes and technologies, and currently recycling represents the only alternative for the social, economic and environmental sustainability of this market, able to minimize toxicity of End-of-Life products, to create a monetary gain and to lead to the independence from foreign resources or critical materials. This paper analyses the current alternatives for the recycling of Lithium-ion batteries, specifically focusing on available procedures for batteries securing and discharging, mechanical pre-treatments and materials recovery processes (i.e. pyro- and hydrometallurgical), and it highlights the pros and cons of treatments in terms of energy consumption, recovery efficiency and safety issues. Target metals (e.g. Cobalt, Nickel and Lithium) are listed and prioritized, and the economic advantage deriving by the material recovery is outlined. An in-depth literature review was conducted, analysing the existing industrial processes, to show the on-going technological solutions proposed by research projects and industrial developments, comparing best results and open issues and criticalities.

Integrating Flotation and Pyrometallurgy for Recovering Graphite and Valuable Metals from Battery Scrap

Since the current volumes of collected end-of-life lithium ion batteries (LIBs) are low, one option to increase the feasibility of their recycling is to feed them to existing metals production processes. This work presents a novel approach to integrate froth flotation as a mechanical treatment to optimize the recovery of valuable metals from LIB scrap and minimize their loss in the nickel slag cleaning process. Additionally, the conventional reducing agent in slag cleaning, namely coke, is replaced with graphite contained in the LIB waste flotation products. Using proper conditioning procedures, froth flotation was able to recover up to 81.3% Co in active materials from a Cu-Al rich feed stream. A selected froth product was used as feed for nickel slag cleaning process, and the recovery of metals from a slag (80%)–froth fraction (20%) mixture was investigated in an inert atmosphere at 1350 °C and 1400 °C at varying reduction times. The experimental conditions in combination with the graphite allowed for a very rapid reduction. After 5 min reduction time, the valuable metals Co, Ni, and Cu were found to be distributed to the iron rich metal alloy, while the remaining fraction of Mn and Al present in the froth fraction was deported in the slag.

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.

Progress and Status of Hydrometallurgical and Direct Recycling of Li-Ion Batteries and Beyond

An exponential market growth of Li-ion batteries (LIBs) has been observed in the past 20 years; approximately 670,000 tons of LIBs have been sold in 2017 alone. This trend will continue owing to the growing interest of consumers for electric vehicles, recent engagement of car manufacturers to produce them, recent developments in energy storage facilities, and commitment of governments for the electrification of transportation. Although some limited recycling processes were developed earlier after the commercialization of LIBs, these are inadequate in the context of sustainable development. Therefore, significant efforts have been made to replace the commonly employed pyrometallurgical recycling method with a less detrimental approach, such as hydrometallurgical, in particular sulfate-based leaching, or direct recycling. Sulfate-based leaching is the only large-scale hydrometallurgical method currently used for recycling LIBs and serves as baseline for several pilot or demonstration projects currently under development. Conversely, most project and processes focus only on the recovery of Ni, Co, Mn, and less Li, and are wasting the iron phosphate originating from lithium iron phosphate (LFP) batteries. Although this battery type does not dominate the LIB market, its presence in the waste stream of LIBs causes some technical concerns that affect the profitability of current recycling processes. This review explores the current processes and alternative solutions to pyrometallurgy, including novel selective leaching processes or direct recycling approaches.

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.