Resource recovery of critically-rare metals by hydrometallurgical recycling of spent lithium ion batteries

Addressing the Reuse of Deep Eutectic Solvents in Li-Ion Battery Recycling: Insights into Dissolution Mechanism, Metal Recovery, Regeneration and Decomposition

Deep eutectic solvents (DESs) have garnered attention in Li-ion battery (LIB) recycling due to their declared eco-friendly attributes and adjustable metal dissolution selectivity, offering a promising avenue for recycling processes. However, DESs currently lack competitiveness compared to mineral acids, commonly used in industrial-scale LIB recycling. Current research primarily focuses on optimizing DES formulation and experimental conditions to maximize metal dissolution yields in standalone leaching experiments. While achieving yields comparable to traditional leaching systems is important, extensive DES reuse is vital for overall recycling feasibility. To achieve this, evaluating the metal dissolution mechanism can assist in estimating DES consumption rates and assessing process makeup stream costs. The selection of appropriate metal recovery and DES regeneration strategies is essential to enable subsequent reuse over multiple cycles. Finally, decomposition of DES components should be avoided throughout the designed recycling process, as by-products can impact leaching efficiency and compromise the safety and environmental friendliness of DES. In this review, these aspects are emphasized with the aim of directing research efforts away from simply pursuing the maximization of metal dissolution efficiency, towards a broader view focusing on the application of DES beyond the laboratory scale.

A closer look at lithium-ion batteries in E-waste and the potential for a universal hydrometallurgical recycling process

The demand for lithium-ion batteries (LiBs) is rising, resulting in a growing need to recycle the critical raw materials (CRMs) which they contain. Typically, all spent LiBs from consumer electronics end up in a single waste stream that is processed to produce black mass (BM) for further recovery. It is desired to design a recycling process that can deal with a mixture of LiBs. Hence, this study investigates the structure and composition of battery modules in common appliances such as laptops, power banks, smart watches, wireless earphones and mobile phones. The battery cells in the module were disassembled into cell casing, cathode, anode and separator. Then, the cathode active materials (CAMs) were characterized in detail with XRD-, SEM-, EDX- and ICP-OES-analysis. No direct link was found between the chemistry of the active materials (NMC, LCO, LMO, LFP etc.) and the application. Various BM samples were submitted to a leaching procedure (2 M H2SO4, 50 °C, 2 h, 60 g BM/L) with varying concentration (0-4 vol%) of H2O2 to study the influence of their chemical composition on the dissolution of Li, Ni, Mn and Co. Only a part of the BMs dissolved completely at 4 vol% H2O2, which was attributed to the oxidation state of the transition metals (TMs). Exact determination of H2O2 consumption by redox titration confirmed this hypothesis.

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.

Closed-loop recycling of lithium iron phosphate cathodic powders via citric acid leaching

Lithium recovery from Lithium-ion batteries requires hydrometallurgy but up-to-date technologies aren't economically viable for Lithium-Iron-Phosphate (LFP) batteries. Selective leaching (specifically targeting Lithium and based on mild organic acids and low temperatures) is attracting attention because of decreased environmental impacts compared to conventional hydrometallurgy. This study analysed the technical and economic performances of selective leaching with 6%vv. H2O2 and citric acid (0.25-1 M, 25 °C, 1 h, 70 g/l) compared with conventional leaching with an inorganic acid (H2SO4 1 M, 40 °C, 2 h, 50 g/l) and an organic acid (citric acid 1 M, 25 °C, 1 h, 70 g/l) to recycle end of life LFP cathodes. After conventional leaching, chemical precipitation allowed to recover in multiple steps Li, Fe and P salts, while selective leaching allowed to recover Fe and P, in the leaching residues and required chemical precipitation only for lithium recovery. Conventional leaching with 1 M acids achieved leaching efficiencies equal to 95 ± 2% for Li, 98 ± 8% for Fe, 96 ± 3% for P with sulfuric acid and 83 ± 0.8% for Li, 8 ± 1% for Fe, 12 ± 5% for P with citric acid. Decreasing citric acid's concentration from 1 to 0.25 M didn't substantially change leaching efficiency. Selective leaching with citric acid has higher recovery efficiency (82 ± 6% for Fe, 74 ± 8% for P, 29 ± 5% for Li) than conventional leaching with sulfuric acid (69 ± 15% for Fe, 70 ± 18% for P, and 21 ± 2% for Li). Also, impurities' amounts were lower with citric acid (335 ± 19 335 ± 19 of S mg/kg of S) than with sulfuric acid (8104 ± 2403 mg/kg of S). In overall, the operative costs associated to 0.25 M citric acid route (3.17€/kg) were lower compared to 1 M sulfuric acid (3.52€/kg). In conclusion, citric acid could be a viable option to lower LFP batteries' recycling costs, and it should be further explored prioritizing Lithium recovery and purity of recovered materials.

Recovery of valuable metals from spent lithium-ion batteries via zinc powder reduction roasting and cysteine leaching

With the annual increase in lithium-ion batteries (LIBs) disposal, valuable resources are being generated with worrying waste, so it is strategically important to recover the critical metals from them. Individual high temperature or leaching processes do not apparently achieve very satisfactory results. In the present work, the reduction with zinc powder was able to convert the lithium in LiNixCoyMnzO2 (NCM) to soluble LiOH, while the reduction and ammonia complexation environment generated by the decomposition of cysteine (Cys) achieved an efficient leaching of transition metals without additional additives. The leaching efficiency of Li can reach more than 92 %, while that of Ni/Co/Mn reaches more than 97 % through the regulation of the parameters of each process. In particular, an in-situ redox mechanism is proposed to explain the efficient leaching of transition metals, which further enriches the theory of spent LIBs recycling and provides a promising idea for various hydrometallurgical extraction systems.

Environment-friendly, efficient process for mechanical recovery of waste lithium iron phosphate batteries

Technology for recycling retired lithium batteries has become increasingly environment-friendly and efficient. In traditional recovery methods, pyrometallurgy or hydrometallurgy is often used as an auxiliary treatment method, which results in secondary pollution and increases the cost of harmless treatment. In this article, a new method for combined mechanical recycling of waste lithium iron phosphate (LFP) batteries is proposed to realize the classification and recycling of materials. Appearance inspections and performance tests were conducted on 1000 retired LFP batteries. After discharging and disassembling the defective batteries, the physical structure of the cathode binder was destroyed under ball-milling cycle stress, and the electrode material and metal foil were separated using ultrasonic cleaning technology. After treating the anode sheet with 100 W of ultrasonic power for 2 minutes, the anode material was completely stripped from the copper foil, and no cross-contamination between the copper foil and graphite was observed. After the cathode plate was ball-milled for 60 seconds with an abrasive particle size of 20 mm and then ultrasonically treated for 20 minutes with a power of 300 W, the stripping rate of the cathode material reached 99.0%, and the purities of the aluminium foil and LFP reached 100% and 98.1%, respectively.

Current Trends in Spent Portable Lithium Battery Recycling

This paper provides an overview of the current state of the field in spent portable lithium battery recycling at both the research and industrial scales. The possibilities of spent portable lithium battery processing involving pre-treatment (manual dismantling, discharging, thermal and mechanical-physical pre-treatment), pyrometallurgical processes (smelting, roasting), hydrometallurgical processes (leaching followed by recovery of metals from the leachates) and a combination of the above are described. The main metal-bearing component of interest is the active mass or cathode active material that is released and concentrated by mechanical-physical pre-treatment procedures. The metals of interest contained in the active mass include cobalt, lithium, manganese and nickel. In addition to these metals, aluminum, iron and other non-metallic materials, especially carbon, can also be obtained from the spent portable lithium batteries. The work describes a detailed analysis of the current state of research on spent lithium battery recycling. The paper presents the conditions, procedures, advantages and disadvantages of the techniques being developed. Moreover, a summary of existing industrial plants that are focused on spent lithium battery recycling is included in this paper.

Optical and quantitative detection of cobalt ion using graphitic carbon nitride-based chemosensor for hydrometallurgy of waste lithium-ion batteries

A hydrometallurgy is one of the most important techniques for recycling waste LIBs, where identifying the exact composition of the metal-leached solution is critical in controlling the metal extraction efficiency and the stoichiometry of the regenerated product. In this study, we report a simple and selective optical detection of high-concentrated Co²⁺ using a graphitic carbon nitride (g-CN)-based fluorescent chemosensor. g-CN is prepared by molten salt synthesis using dicyandiamide (DCDA) and LiI/KI. The mass ratio of LiI/KI to DCDA modifies the resulting g-CN (CNI) in terms of in-plane molecular distances of base sites including cyano functional groups (─CN) and fluorescent emission wavelength via nucleophilic substitution. The fluorescent sensing performance of CNIs is evaluated through photoluminescence (PL) emission spectroscopy in a broad Co²⁺ concentration range (10^-4-10⁰ M). The correlation between the surface exposure of hidden nitrogen pots (base sites) and PL intensity change is achieved where the linear relationship between the PL quenching and the logarithm of Co²⁺ concentration in the analyte solution is well established with the regression of 0.9959. This study will provide the design principle of the chemosensor suitable for the fast and accurate optical detection of Co²⁺ present in a broad concentration range for hydrometallurgy for the recycling of waste LIBs.

Recovery of critical metals from spent Li-ion batteries: Sequential leaching, precipitation, and cobalt-nickel separation using Cyphos IL104

This study presents a novel recycling scheme for spent Li-ion batteries that involves the leaching of lithium in hot water followed by the dissolution of all transition metals in HCl solution and their separation using the ionic liquid Cyphos IL104. The parametric studies revealed that >84 % Li was dissolved while the cathode material was leached at 90 °C for 2 h. Approximately 98 % Li from the non-acidic solution was directly precipitated as Li2CO3 at a Li+:CO32- ratio of 1:1.5. The transition metals from the Li-depleted cathode mass were efficiently (>98 %) dissolved in 3.0 mol·L-1 HCl at 90 °C for a 3 h leaching process. Manganese from the chloride leach liquor was selectively precipitated by adding KMnO4 at a 1.25-fold higher quantity than the stoichiometric ratio, pH value 2.0, and temperature 80 °C. The remaining co-existing metals (Ni and Co) were separated from the chloride solution by contacting it with a phosphonium-based ionic liquid at an equilibrium pH value of 5.4 and an organic-to-aqueous phase ratio of 2/3. The loaded ionic liquid was quantitatively stripped in 2.0 mol·L-1 H2SO4 solution, which yielded high-purity CoSO4·xH2O crystals after evaporation of the stripped liquor. Subsequently, ∼99 % nickel was recovered as nickel carbonate [NiCO3·2Ni(OH)2] from the Co-depleted raffinate by the precipitation performed at Ni2+:CO32- ratio of 1:2.5, pH value of 10.8, and temperature of 50 °C. Finally, a process flow with mass and energy balances yielding a high recovery rate of all metals in the exhausted cathode powder of spent LiBs was proposed.

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.

Discharge of lithium-ion batteries in salt solutions for safer storage, transport, and resource recovery

The use of lithium-ion batteries (LIBs) has grown in recent years, making them a promising source of secondary raw materials due to their rich composition of valuable materials, such as Cobalt and Nickel. Recycling LIBs can help reduce fossil energy consumption, CO₂ emissions, environmental pollution, and consumption of valuable materials with limited supplies. On the other hand, the hazards associated with spent LIBs recycling are mainly due to fires and explosions caused by unwanted short-circuiting. The high voltage and reactive components of end-of-life LIBs pose safety hazards during mechanical processing and crushing stages, as well as during storage and transportation. Electrochemical discharge using salt solutions is a simple, quick, and inexpensive way to eliminate such hazards. In this paper, three different salts (NaCl, Na₂S, and MgSO₄) from 12% to 20% concentration are investigated as possible candidates. The effectiveness of discharge was shown to be a function of molarity rather than ionic strength of the solution. Experiments also showed that the use of ultrasonic waves can dramatically improve the discharge process and reduce the required time more than 10-fold. This means that the drainage time was reduced from nearly 1 day to under 100 minutes. Finally, a practical setup in which the tips of the batteries are directly immersed inside the salt solution is proposed. This creative configuration can fully discharge the batteries in less than 5 minutes. Due to the fast discharge rates in this configuration, sedimentation and corrosion are also almost entirely avoided.

An overview of global power lithium-ion batteries and associated critical metal recycling

The rapid development of lithium-ion batteries (LIBs) in emerging markets is pouring huge reserves into, and triggering broad interest in the battery sector, as the popularity of electric vehicles (EVs)is driving the explosive growth of EV LIBs. These mounting demands are posing severe challenges to the supply of raw materials for LIBs and producing an enormous quantity of spent LIBs, bringing difficulties in the areas of resource allocation and environmental protection. This review article presents an overview of the global situation of power LIBs, aiming at different methods to treat spent power LIBs and their associated metals. We provide a critical review of power LIB supply chain, industrial development, waste treatment strategies and recycling, etc. Power LIBs will form the largest proportion of the battery industry in the next decade. The analysis of the sustainable supply of critical metal materials is emphasized, as recycling metal materials can alleviate the tight supply chain of power LIBs. The existing significant recycling practices that have been recognized as economically beneficial can promote metal closed-loop recycling. Scientific thinking needs to innovate sustainable and cost-effective recycling technologies to protect the environment because of the chemicals contained in power LIBs.

Closed-loop selective recycling process of spent LiNixCoyMn1-x-yO2 batteries by thermal-driven conversion

The consumption of lithium-ion batteries raises raw material demand for and the pressure on ecological sustainability. Metals can be recovered in shorter paths while considerably boosting material use, hence selective recycling of specific elements is becoming a hotspot. This paper proposes a thermally-driven closed-loop recycling process for scrap LiNi_1/3Co_1/3Mn_1/3O₂ cathodes, in which Li is efficiently extracted by water leaching. Then, by combining the leaching residue with Li₂CO₃, a solid-phase synthesis is carried out, with Li being targeted to heal into Ni-Co-Mn-O to construct the layered structure. The electrochemical performance of the resynthesized cathode material is comparable to that of the commercial LiNi_0.5Co_0.2Mn_0.3O₂ (NCM523) material. During the thermal-driven conversion, solid-state processes can be observed. To ensure charge conservation, Li⁺ in the unstable layered structure is released and mixed with SO₄^2- to produce Li₂SO₄, and lattice oxygen escapes and transforms with Ni²⁺ to generate NiO. For the resynthesized process, the spherical shape of Ni-Co-Mn-O is largely retained. Notably, sulfur is remained in the form of SO₄^2- throughout the closed-loop process and is therefore free of contamination. The thermal-driven conversion recycling process revealed in this study will encourage researchers to ensure more efforts in efficient and selective recovery for sustainable energy storage of rechargeable batteries.

A novel method for carbon removal and valuable metal recovery by incorporating steam into the reduction-roasting process of spent lithium-ion batteries

Oxygen-free roasting could efficiently achieve the recovery of valuable metals from spent lithium-ion batteries (LIBs), but the roasted products have the drawbacks of a high carbon (C) content and a complex separation process. Hence, in this study, a new method incorporating steam (H₂O) into the reduction-roasting recovery process of spent LIBs (steam roasting) was proposed to realize carbon removal and valuable metal recovery simultaneously. The influence of steam on the reduction-roasting process of spent LiNi_0.6Co_0.2Mn_0.2O₂ batteries (NCM) was investigated through experimental methods and thermodynamic analysis. The results indicated that the addition of steam could dramatically facilitate the decomposition and reduction process of spent NCM, and the carbon removal efficiency could reach 84%. H₂O only acted on the reaction process of the anode material, and the main component C could be efficiently gasified by steam to produce hydrogen (H₂) and carbon monoxide (CO), which could significantly accelerate the reduction process of CoO and NiO. The optimal conditions for valuable metal recovery and carbon removal were a H₂O/C mole ratio of 5:1 and a reduction-roasting temperature of 1123 K. After steam roasting, the magnetic recovery efficiencies of Co and Ni were as high as 90% and 93%, respectively. The final recovery products were Co, Ni, and Li₂CO₃ with high purities. Therefore, this study is expected to provide a novel approach to achieve efficient disposal and recovery of metals from spent LIBs.

O2-enriched microbial activity with pH-sensitive solvo-chemical and electro-chlorination strategy to reclaim critical metals from the hazardous waste printed circuit boards

An innovative process integration for the sustainable recovery of critical metals from waste printed circuit boards (WPCBs) is demonstrated. In the acid pre-treatment of WPCBs, > 95% of highly toxic metals lead and tin could dissolve after 240 min of contact in 4.0 mol L^-1 HNO₃. Thereafter, the microbial activity of Sulfobacillus thermosulfidooxidans (strain RDB) under intense aeration is found favorable for base metals' liberation. ~92% copper, 89% nickel, and 93% zinc get extracted at the optimal condition of O₂-mixed-aeration, 30%; pulp density, 10 g L^-1; aeration rate, 0.5 L min^-1; sulfur dosage, 2%; temperature, 45 °C; and duration, 21 days. Quantitative separation of base metals is achieved using ketoxime as a function of equilibrium pH that yielding pH_0.5 order: Cu (1.45) < Ni (5.7) < Zn (8.1). The residual gold from WPCBs is uniquely leached (~99% efficiency) in brine solution (2.0 mol L^-1 NaCl) under the electro-chlorination rate, 0.62 mmol min^-1; dissolution pH, 1.0; pulp density, 20 g L^-1; temperature, 30 °C; and time, 60 min. Subsequently, gold from brine solution is solvated with tri-butyl-phosphate at pH_eq, ≤ 0.5, forming [2(RP=O)·HAuCl₄·H₂O]¯ complex in the organic phase. Finally, > 99% of high-purity gold is stripped from loaded organic while contacting ammoniacal thiosulfate solution in two-stages of counter-current flow.

A process of leaching recovery for cobalt and lithium from spent lithium-ion batteries by citric acid and salicylic acid

There is great economic and environmental value in recovering valuable metal ions from spent lithium-ion batteries (LIBs). A novel method that employs organic acid recovery using citric acid and salicylic acid was used to enhance the leaching of metal ions from the cathode materials of spent LIBs. The effects of the acid concentration, reducing agent content, solid to liquid (S : L) ratio, temperature, and leaching time were systematically analyzed and the optimal acid leaching process condition was determined through the results. The kinetics of the leaching process with different temperatures was analyzed to explore and verify the relationship between the leaching mechanism and temperature. The results of TG/DSC analysis showed that the optimum calcination temperature was 500 °C for 1 h and 600 °C for 3 h. The XRD and micromorphology analysis results showed that cathode material powders without impurities were obtained after pretreatment. The experimental results demonstrated that the optimal leaching efficiencies of the metals ions were 99.5% Co and 97% Li and the optimal corresponding condition was 1.5 M citric acid, 0.2 M salicylic acid, a 15 g L⁻¹ S : L ratio, 6 vol% H₂O₂, 90 °C, and 90 min. Afterward, the infrared tests and SEM morphologies results indicated that only salicylic acid was present in the residue after filtration because of the microsolubility of the salicylic acid. Finally, it was obvious that the temperature had a great influence on the leaching process as observed through the kinetics and thermodynamics analyses, while the E_a values for Co and Li were obtained as 37.96 kJ mol⁻¹ and 25.82 kJ mol⁻¹ through the kinetics model. The whole process was found to be efficient and reasonable for recovering valuable metals from the industrial electrodes of spent LIBs.

A new mixed organic acid of citric acid and salicylic acid is proposed to recover valuable Co and Li ions from spent LIBs. Under the optimum leaching conditions, the leaching efficiencies of Co and Li ions can reach 99.5% and 97%.

Converting Spent LiFePO4 Battery into Zeolitic Phosphate for Highly Efficient Heavy Metal Adsorption

Developing efficient recycling technologies for large-scale spent batteries is the key to build a zero-waste city. Herein, a [Al_8.5Fe_0.5P₁₂O₄₈]·[C₂₄H₇₂N₁₆]·[Li·4H₂O]·[12H₂O] (AlFePO-Li) zeolite, crystallizing in space group I4̅3m with a = 16.6778(3) Å, has been constructed via the hydrothermal treatment of spent LiFePO₄ battery. Benefiting from the three-dimensional 12-member-ring channels in its structure and chemical adsorption, excellent Pb²⁺ removal capacity up to 723.8 mg g^-1 has been achieved. Detailed adsorption mechanism study revealed that the cation exchange capacity is significantly contributed by ion exchange of the protonated organic amine cations in the zeolite channel and the protons from the framework dangling phosphate group. This work demonstrates a novel method of reutilizing spent LIBs to construct zeolite for heavy metal removal. It is of great importance to achieve sustainable development based on the "resource utilization" and "trash-to-treasure" strategy.

Biotreatment for the spent lithium-ion battery in a three-module integrated microbial-fuel-cell recycling system

A bio-electrochemically (BE) recycling platform was assembled to recover Li and Co from the cathodic materials of spent LIBs in one integrated system. The BE platform consists of three microbial-fuel-cell (MFC) subsystems, including MFC-A, MFC-B, and MFC-C. Co and Li were smoothly recovered from the cathodic materials in the assembled platform. The initial pH and the loading ratios of LiCoO₂ both significantly influenced the leaching efficiencies of Li and Co in MFC-A. Approximately 45% Li and 93% Co were simultaneously released through the reduction of LiCoO₂ at the initial pH of 1 and the loading ratios of LiCoO₂ of 0.2 g/L. The (NH₄)₂C₂O₄-modified granular activated carbons (GAC) with a thickness of 1.5 cm was favorably stacked adjacent to the cathode of the MFC-B system. About 98% of removal efficiency (RE_Co1) and 96% of recovery efficiency (RE_Co2) of Co were achieved in MFC-B under optimum conditions. The dosing concentration of Li⁺ lower than 2 mg/L and the (NH₄)₂CO₃ of 0.01-0.02 M were conducive to enhancing the recovery of Li from raffinate and guaranteed the higher power output and coulombic efficiencies in MFC-C. The continuous release of CO₂ caused by exoelectrogenic microorganisms on the biofilm facilitated the precipitation of Li₂CO₃.

Recycling of electrode materials from spent lithium-ion power batteries via thermal and mechanical treatments

This study developed a physical separation process that recovers active cathode materials from current collectors in spent lithium-ion power batteries (LIBs). The physical separation process, implemented via thermal and mechanical treatments, was examined based on cohesive zone models (CZMs) and verified by physical separation experiments. The most efficient condition was determined by optimising the key parameters (temperature and time) of selective heating. Among several mechanical separation methods, high-speed shearing best separates positive electrode materials into active cathode materials (LiFePO₄) and current collectors (Al fragments). The separation effect was verified by computing the dissociation rate and microscopic observation of the separated materials. The feasibility and efficiency of the above process were assessed in a work-of-force analysis, flow field simulation, high-speed crushing experiment and material property analysis. The above analyses realised a feasible, efficient and environmentally friendly separation route without changing the chemical structure and properties of the electrode materials. Under non-high (energy-conserving) temperature conditions, the LiFePO₄ dissociation rate stabilises at 80-85%. Under high-speed crushing, the LiFePO₄ dissociation rate reaches 85% at 32,000-r/min crushing and a maximum shearing velocity of the blade edge v ≈ 500 m/s. This approach can effectively recycle electrode materials, gain valuable resources and can be used to recycle and utilise spent LIBs, thus addressing two grave issues - environmental pollution and resource wastage to achieve the sustainable development of LIBs and electric vehicle industry.

Early-Stage Recovery of Lithium from Tailored Thermal Conditioned Black Mass Part I: Mobilizing Lithium via Supercritical CO2-Carbonation

In the frame of global demand for electrical storage based on lithium-ion batteries (LIBs), their recycling with a focus on the circular economy is a critical topic. In terms of political incentives, the European legislative is currently under revision. Most industrial recycling processes target valuable battery components, such as nickel and cobalt, but do not focus on lithium recovery. Especially in the context of reduced cobalt shares in the battery cathodes, it is important to investigate environmentally friendly and economic and robust recycling processes to ensure lithium mobilization. In this study, the method early-stage lithium recovery (“ESLR”) is studied in detail. Its concept comprises the shifting of lithium recovery to the beginning of the chemo-metallurgical part of the recycling process chain in comparison to the state-of-the-art. In detail, full NCM (Lithium Nickel Manganese Cobalt Oxide)-based electric vehicle cells are thermally treated to recover heat-treated black mass. Then, the heat-treated black mass is subjected to an H2O-leaching step to examine the share of water-soluble lithium phases. This is compared to a carbonation treatment with supercritical CO2, where a higher extent of lithium from the heat-treated black mass can be transferred to an aqueous solution than just by H2O-leaching. Key influencing factors on the lithium yield are the filter cake purification, the lithium separation method, the solid/liquid ratio, the pyrolysis temperature and atmosphere, and the setup of autoclave carbonation, which can be performed in an H2O-environment or in a dry autoclave environment. The carbonation treatments in this study are reached by an autoclave reactor working with CO2 in a supercritical state. This enables selective leaching of lithium in H2O followed by a subsequent thermally induced precipitation as lithium carbonate. In this approach, treatment with supercritical CO2 in an autoclave reactor leads to lithium yields of up to 79%.

Selective Precipitation of Metal Oxalates from Lithium Ion Battery Leach Solutions

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

Is Recycling Always the Best Option? Environmental Assessment of Recycling of Seashell as Aggregates in Noise Barriers

Waste recycling is an essential part of waste management. The concrete industry allows the use of large quantities of waste as a substitute for a conventional raw material without sacrificing the technical properties of the product. From a circular economy point of view, this is an excellent opportunity for waste recycling. Nevertheless, in some cases, the recycling process can be undesirable because it does not involve a net saving in resource consumption or other environmental impacts when compared to the conventional production process. In this study, the environmental performance of conventional absorption porous barriers, composed of 86 wt % of natural aggregates and 14 wt % cement, was compared with barriers composed of 80 wt % seashell waste and 20 wt % cement through an attributional cradle-to-grave life cycle assessment. The results show that, for the 11 environmental impact categories considered, the substitution of the natural aggregates with seashell waste involves higher environmental impacts, between 32% and 267%. These results are justified by the high contribution to these impacts of the seashell waste pre-treatment and the higher cement consumption. Therefore, the recycling of seashells in noise barrier manufacturing is not justified from an environmental standpoint with the current conditions. In this sense, it could be concluded that life cycle assessments should be carried out simultaneously with the technical development of the recycling process to ensure a sustainable solution.

Electrochemical recovery of cobalt using nanoparticles film of copper hexacyanoferrates from aqueous solution

Nanoparticles film of copper metal hexacyanoferrates (CuHCF) was fabricated to electrochemically separate Co²⁺ in aqueous solutions under various conditions such as applied potential, solution pHs, initial concentrations, contact time and coexisting ions. Results showed that the removal efficiency conducted in reduction potential was obviously higher than that in oxidation potential. The optimal pH for Co²⁺ adsorption occurred at 8.0. Coexisting ions studies revealed that Co²⁺ could be removed from aqueous solutions containing Li⁺, Cu²⁺ and Al³⁺. Considering that cobalt and lithium are the main metallic elements in LiCoO₂, the effect of different ionic strengths (IS) of LiNO₃ (0.5, 1, 2, 5, 10) on adsorption was further investigated. Results showed that IS of LiNO₃ had little impact on the removal efficiency of Co²⁺, which indicated the potential of selective recovery of cobalt from LiCoO₂ in spent lithium-ion batteries. X-ray energy-dispersion spectroscopy (EDS) confirmed that the Co²⁺ could be adsorbed effectively onto CuHCF film. The adsorption was well described by Langmuir isotherm and the maximum sorption capacity is 218.82 mg/g. The kinetic rate of Co²⁺ adsorption was rapid initially and attained equilibrium within 60 min, and the data well fitted the Redlich-Peterson and the Elovich model, implying a chemisorption dominated process.

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.

Production of Ferronickel Concentrate from Low-Grade Nickel Laterite Ore by Non-Melting Reduction Magnetic Separation Process

The production of ferronickel concentrate from low-grade nickel laterite ore containing 1.31% nickel (Ni) was studied by the non-melting reduction magnetic separation process. The sodium chloride was used as additive and coal as a reductant. The effects of roasting temperature, roasting duration, reductant dosage, additive dosage, and grinding time on the grade and recovery were investigated. The optimal reduction conditions are a roasting temperature of 1250 °C, roasting duration of 80 min, reductant dosage of 10%, additive dosage of 5%, and a grinding time of 12 min. The grades of nickel and iron are improved from 2.13% and 51.12% to 8.15% and 64.28%, and the recovery of nickel is improved from 75.40% to 97.76%. The research results show that the additive in favor of the phase changes from lizardite phase to forsterite phase. The additive promotes agglomeration and separation of nickel and iron.

Recovery methods and regulation status of waste lithium-ion batteries in China: A mini review

Heavy metals such as Co, Li, Mn, Ni, etc. and organic compounds enrich spent lithium-ion batteries (LIBs). These batteries seriously threaten human health and the environment. Meanwhile, with the development of new energy vehicles, the shortage of valuable metal resources which are used as raw materials for power batteries is becoming a serious problem. Using proper methods to recycle spent LIBs can both save resources and protect the environment. Pyrometallury is a kind of recycling method that is operated under high temperature with the aim of recovering useful metals after pre-treatment and organic binder removal with the characteristic of high temperature and it is easy to operate. Hydrometallurgy is characterized by high recovery efficiency, low reaction energy consumption, and high reaction rate, and is widely used in the recycling process of spent LIBs. During biometallurgy, valuable metals in the spent LIBs are extracted by microbial metabolism or microbial acid production processes. Since the drive for green and low secondary pollution, biometallurgy as well as solvent extraction and the electrochemical method have earned more attention during recent years. This mini-review analyzes the relationship between the emergence of new energy vehicles and the recycling status of spent LIBs. Meanwhile, this paper also consists of detailed treatment and recycling methods for LIBs and provides a summary of the management regulations of current waste for LIBs. What is more, the main challenges and further prospects in terms of LIBs management in China are analyzed.

Regeneration and characterization of LiNi0.8Co0.15Al0.05O2 cathode material from spent power lithium-ion batteries

The use and scrap of lithium ion batteries, especially power lithium ion batteries in China, are increasing every year. Regeneration of spent battery materials is not only important for environmental protection and resource saving, but also for the production of high value-added materials. In this research, spent power lithium-ion battery cathode material LiNi_1-xCo_xO₂ was acid-leached and a polymetallic leaching solution containing Li, Ni, Co, Al and Cu was obtained. Cu was extracted from the leachate by using CP-150 (2-hydroxy-5-nonyl salicylaldehyde oxime). The optimal conditions were found to be organic: aqueous phase ratio (O/A) = 2:1, extraction agent concentration of 30%, and pH = 3. The precursor was prepared by coprecipitation of the leachate after Cu removal. Then, cathode material of lithium nickel cobalt aluminate LiNi_0.8Co_0.15Al_0.05O₂ was synthesized under the optimal conditions of n (precursor): n (lithium carbonate) = 1:1.1, calcination temperature of 800 °C for 15 h. The regenerated LiNi_0.8Co_0.15Al_0.05O₂ product prepared under the optimized conditions was in a pure phase with a layered structure and a smooth surface morphology. The first charge specific capacity was 248.7 mAh/g, and the discharge specific capacity was 162 mAh/g. The interfacial impedance was 119 Ω. The 50th-cycle discharge specific capacity was 149.1 mAh/g, and the capacity retention rate was high as 92%. Therefore, the regenerated cathode material exhibited good performance.

Recycling valuable metals from spent lithium-ion batteries by ammonium sulfite-reduction ammonia leaching

The cathode powder is obtained by wet crushing and screening, and the leaching behavior of Li, Ni, Co, Cu, and Al is then investigated using a ternary leaching system composed of ammonia, ammonium sulfite, and ammonium bicarbonate. Ammonium sulfite is necessary as a reductant to improve the Li, Ni, and Co leaching efficiencies, and ammonium bicarbonate acts as a buffer in ammoniacal solutions. A detailed understanding of the selective leaching process is obtained by investigating the effects of parameters such as the leaching reagent composition, leaching time (0-300 min), temperature (40-90 °C), solid-to-liquid ratio (10-50 g/L), and agitation speed (300-700 rpm). It is found that Ni and Cu could be almost fully leached out, while Al is hardly leached and Li(60.53%) and Co(80.99%) exhibit a moderate leaching efficiency. The results show that the optimum solid-liquid ratio of the leaching system is 20 g/L, and the increase of temperature and reaction time is beneficial to metal leaching. The leaching kinetics analysis shows that the chemical reaction control explains the leaching behavior of Li, Ni, and Co well. Therefore, this work may be beneficial for further recycling valuable metals from leaching solutions by introducing an extraction agent.

A process for combination of recycling lithium and regenerating graphite from spent lithium-ion battery

Recycling lithium and graphite from spent lithium-ion battery plays a significant role in mitigation of lithium resources shortage, comprehensive utilization of spent anode graphite and environmental protection. In this study, spent graphite was firstly collected by a two-stage calcination. Secondly, under the optimal conditions of 1.5 M HCI, 60 min and solid-liquid ratio (S/L) of 100 g·L^-1, the collected graphite suffers simple acid leaching to make almost 100% lithium, copper and aluminum in it into leach liquor. Thirdly, 99.9% aluminum and 99.9% copper were removed from leach liquor by adjusting pH first to 7 and then to 9, and thenthe lithium was recovered by adding sodium carbonate in leach liquor to form lithium carbonate with high purity (>99%). The regenerated graphite is found to have high initial specific capacity at the rate of 37.2 mA·g^-1 (591 mAh·g^-1), 74.4 mA·g^-1 (510 mAh·g^-1) and 186 mA·g^-1 (335 mAh·g^-1), and with the high retention ratio of 97.9% after 100 cycles, it also displays excellent cycle performance at high rate of 372 mA·g^-1. By this process, copper and lithium can be recovered and graphite can be regenerated, serving as a sustainable approach for the comprehensive utilization of anode material from spent lithium-ion battery.

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

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

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