Recovery of cobalt from spent lithium-ion batteries using supercritical carbon dioxide extraction

Lithium and cobalt extraction from LiCoO2 assisted by p(VBPDA-co-FDA) copolymers in supercritical CO2

Supercritical CO2 (scCO2) extraction assisted by complexing copolymers is a promising process to recover valuable metals from lithium-ion batteries (LIBs). CO2, in addition to being non-toxic, abundant and non-flammable, allows an easy separation of metal-complexes from the extraction medium by depressurization, limiting the wastewater production. In this study, CO2-philic gradient copolymers bearing phosphonic diacid complexing groups (poly(vinylbenzylphosphonic diacid-co-1,1,2,2-tetrahydroperfluorodecylacrylate), p(VBPDA-co-FDA)) were synthesized for the extraction of lithium and cobalt from LiCoO2 cathode material. Notably, the copolymer was able to play the triple role of leaching agent, complexing agent and surfactant. The proof of concept for leaching, complexation and extraction was achieved, using two different extraction systems. A first extraction system used aqueous hydrogen peroxide as reducing agent while it was replaced by ethanol in the second extraction system. The scCO2 extraction conditions such as extraction time, temperature, functional copolymer concentration, and the presence of additives were optimized to improve the metals extraction from LiCoO2 cathode material, leading to an extraction efficiency of Li and Co up to ca. 75 % at 60 °C and 250 bar.

Resource Recovery of Spent Lithium-Ion Battery Cathode Materials by a Supercritical Carbon Dioxide System

The increasing global market size of high-energy storage devices due to the boom in electric vehicles and portable electronics has caused the battery industry to produce a lot of waste lithium-ion batteries. The liberation and de-agglomeration of cathode material are the necessary procedures to improve the recycling derived from spent lithium-ion batteries, as well as enabling the direct recycling pathway. In this study, the supercritical (SC) CO2 was innovatively adapted to enable the recycling of spent lithium-ion batteries (LIBs) based on facilitating the interaction with a binder and dimethyl sulfoxide (DMSO) co-solvent. The results show that the optimum experimental conditions to liberate the cathode particles are processing at a temperature of 70 °C and 80 bar pressure for a duration of 20 min. During the treatment, polyvinylidene fluoride (PVDF) was dissolved in the SC fluid system and collected in the dimethyl sulfoxide (DMSO), as detected by the Fourier Transform Infrared Spectrometer (FTIR). The liberation yield of the cathode from the current collector reaches 96.7% under optimal conditions and thus, the cathode particles are dispersed into smaller fragments. Afterwards, PVDF can be precipitated and reused. In addition, there is no hydrogen fluoride (HF) gas emission due to binder decomposition in the suggested process. The proposed SC-CO2 and co-solvent system effectively separate the PVDF from Li-ion battery electrodes. Thus, this approach is promising as an alternative pre-treatment method due to its efficiency, relatively low energy consumption, and environmental benign features.

Photocatalytic Reduction of Methylene Blue by Surface-Engineered Recombinant Escherichia coli as a Whole-Cell Biocatalyst

A novel Escherichia coli strain, created by engineering its cell surface with a cobalt-binding peptide CP1, was investigated in this study. The recombinant strain, pBAD30-YiaT-CP1, was structurally modeled to determine its cobalt-binding affinity. Furthermore, the effectiveness and specificity of pBAD30-CP1 in adsorbing and extracting cobalt from artificial wastewater polluted with the metal were investigated. The modified cells were subjected to cobalt concentrations (0.25 mM to 1 mM) and pH levels (pH 3, 5, 7, and 9). When exposed to a pH of 7 and a cobalt concentration of 1 mM, the pBAD30-CP1 strain had the best cobalt recovery efficiency, measuring 1468 mol/g DCW (Dry Cell Weight). Furthermore, pBAD30-CP1 had a higher affinity for cobalt than nickel and manganese. Field Emission Scanning Electron Microscopy (FE-SEM), Transmission Electron Microscopy (TEM), and Energy-Dispersive X-ray Spectroscopy (EDS) were used to examine the physiochemical parameters of the recombinant cells after cobalt adsorption. These approaches revealed the presence of cobalt in a bound state on the cell surface in the form of nanoparticles. In addition, the cobalt-binding recombinant strains were used in the photocatalytic reduction of methylene blue, which resulted in a 59.52% drop in the observed percentage. This study shows that modified E. coli strains have the potential for efficient cobalt recovery and application in environmental remediation operations.

Toward Sustainable All Solid-State Li-Metal Batteries: Perspectives on Battery Technology and Recycling Processes

Lithium (Li)-based batteries are gradually evolving from the liquid to the solid state in terms of safety and energy density, where all solid-state Li-metal batteries (ASSLMBs) are considered the most promising candidates. This is demonstrated by the Bluecar electric vehicle produced by the Bolloré Group, which is utilized in car-sharing services in several cities worldwide. Despite impressive progress in the development of ASSLMBs, their avenues for recycling them remain underexplored, and combined with the current explosion of spent Li-ion batteries, they should attract widespread interest from academia and industry. Here, the potential challenges of recycling ASSLMBs as compared to Li-ion batteries are analyzed and the current progress and prospects for recycling ASSLMBs are summarized and analyzed. Drawing on the lessons learned from Li-ion battery recycling, it is important to design sustainable recycling technologies before ASSLMBs gain widespread market adoption. A battery-recycling-oriented design is also highlighted for ASSLMBs to promote the recycling rate and maximize profitability. Finally, future research directions, challenges, and prospects are outlined to provide strategies for achieving sustainable development of ASSLMBs.

Coupling the recovery of spent lithium-ion batteries and the treatment of phenol wastewater: A "treating waste with waste" strategy

The recovery of spent lithium-ion batteries and the treatment of phenol wastewater are both environmental and social issues. In this study, the enhanced recovery of spent lithium-ion batteries and the efficient treatment of phenol wastewater are smartly coupled via a "treating waste with waste" strategy. Under optimal conditions, the leaching process involving phenol achieves 98% and 96% efficiency for Co and Li, respectively. After precipitation, Co and Li could be recovered as Co(OH)2 and Li2CO3, and the precipitated Co(OH)2 was further calcined to generate Co3O4. Furthermore, the organic contaminants that remained in the waste-leaching solution could be removed by a spent graphite-activating peroxymonosulfate (PMS) process. It is noteworthy that the total organic carbon (TOC) in the waste-leaching solution could be removed using fewer PMS compared with the original phenol wastewater owing to the pre-oxidation of phenol during the leaching process, further confirming the advantage of this "treating waste with waste" strategy.

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.

Progress, Key Issues, and Future Prospects for Li-Ion Battery Recycling

The overuse and exploitation of fossil fuels has triggered the energy crisis and caused tremendous issues for the society. Lithium-ion batteries (LIBs), as one of the most important renewable energy storage technologies, have experienced booming progress, especially with the drastic growth of electric vehicles. To avoid massive mineral mining and the opening of new mines, battery recycling to extract valuable species from spent LIBs is essential for the development of renewable energy. Therefore, LIBs recycling needs to be widely promoted/applied and the advanced recycling technology with low energy consumption, low emission, and green reagents needs to be highlighted. In this review, the necessity for battery recycling is first discussed from several different aspects. Second, the various LIBs recycling technologies that are currently used, such as pyrometallurgical and hydrometallurgical methods, are summarized and evaluated. Then, based on the challenges of the above recycling methods, the authors look further forward to some of the cutting-edge recycling technologies, such as direct repair and regeneration. In addition, the authors also discuss the prospects of selected recycling strategies for next-generation LIBs such as solid-state Li-metal batteries. Finally, overall conclusions and future perspectives for the sustainability of energy storage devices are presented in the last chapter.

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.

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.

Efficient recovery of valuable metals from cathode materials of spent LiCoO2 batteries via co-pyrolysis with cheap carbonaceous materials

Recovery of valuable metals from spent Li-ion batteries has prominent economic and environmental benefits. In this study, a novel approach for recycling valuable metals from spent LiCoO₂ batteries via co-pyrolysis with three different carbonaceous materials (waste polyethylene, biomass, and coal)) was proposed and evaluated. The thermodynamic analysis proved that carbonaceous materials (mainly carbon) were theoretically able to facilitate the decomposition process of LiCoO₂. The promotion effect on LiCoO₂ decomposition was in the following order: coal > biomass > polyethylene, and the decomposition temperature of LiCoO₂ could significantly reduce by 400 °C via adding coal. The char produced from the carbonaceous materials, rather than the volatiles, played an important role in LiCoO₂ decomposition and reduction. The pyrolysis products of LiCoO₂ and coal mixture exhibited typical superparamagnetism and hysteresis behaviours, which benefitted the subsequent magnetic separation. The recovery rates of Co and Li were sensitive to the pyrolysis temperature and residence time, respectively. A high proportion of Co was in the form of CoO below 800 °C and had not been completely reduced, leading to the relatively lower recovery rates of Co below 800 °C. The optimal recovery rates of Co (96.8%) and Li (88.7%) were obtained at the pyrolysis temperature of 800 °C and the residence time of 10 min. The final recovery products were Co and Li₂CO₃ with rather high crystallinities and purities. Therefore, this study provided a novel approach for the efficient recycling of valuable metals from spent Li-ion batteries with high application prospects.

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.

Solvent extraction for recycling of spent lithium-ion batteries

Up to now, solvent extraction not only recycle valuable metals (i.e., Ni, Co, Mn and Li) from the leach liquor of spent cathode materials, but also apply to treat spent electrolyte. This paper summarizes the development of solvent extraction in the field of recycling spent lithium-ion batteries (LIBs) from the aspects of principle, technology and industrialization. Meanwhile, the paper also comments on the challenges and opportunities for the solvent extraction facing in the recycling of spent LIBs.

Review on metal dissolution characteristics and harmful metals recovery from electronic wastes by supercritical water

Supercritical water (SCW) technology can be applied as an efficient and environment-friendly method to recover toxic or complex chemical wastes. Separation and chemical reactions under supercritical conditions may be realized by changing the temperature, pressure, and other operating parameters to adjust the physical and chemical properties of water. However, salt deposition and corrosion are often encountered during the treatment of inorganic substances, which will hinder the commercial applications of SCW technology. The solubility of salt in high pressure/temperature water forms the theoretical basis for studying the recovery of metal salts in supercritical water and understanding salt deposition. Therefore, this work systematically and objectively reviews different research methods used to analyze salt solubility in high pressure/temperature water, including the experimental method, prediction theoretical modeling, and computer simulation method; the research status and existing data of this parameter are also analyzed. The purpose of this review is to provide ideas and references for follow-up research by providing a comprehensive overview of salt solubility research methods and the current situation. Suggestions for more efficient metal recovery through technology integration are also provided.

Electronic wastes: A near inexhaustible and an unimaginably wealthy resource for water splitting electrocatalysts

E-wastes comprise complex combinations of potentially toxic elements that cause detrimental effects of the environmental contamination; besides their posing threat, most of the products also contain valuable and recoverable materials (Li, Au, Ag, W, Se, Te, etc.), which make them distinct from other forms of industrial wastes. Most of these value-added elements which are primarily employed in electronic goods are disposed of by incineration and land-filling. This is a serious issue besides just environmental pollution, as IUPAC recognized that such ignorance of or poor attention to e-waste recycling has put several elements in the periodic table to the list of endangered elements. Recycling these wastes utilized for electrocatalytic water splitting to produce H₂. These recovered e-wastes materials are used as electrocatalysts for the water-splitting, additives to enhance reaction kinetics, and substrate electrodes as well. Recycling and recovery of value-added materials in the view of applying them to electrocatalytic water splitting with endangered elements' perspective have not been covered by any recent review so far. Hence, this review is dedicated to discussing the opportunities available with recycling e-wastes, types of value-added materials that can be recovered for water splitting, strategies exploited, and prospects are discussed in details.

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

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

Cobalt Recovery from Li-Ion Battery Recycling: A Critical Review

The increasing demand for Li-ion batteries for electric vehicles sheds light upon the Co supply chain. The metal is crucial to the cathode of these batteries, and the leading global producer is the D.R. Congo (70%). For this reason, it is considered critical/strategic due to the risk of interruption of supply in the short and medium term. Due to the increasing consumption for the transportation market, the batteries might be considered a secondary source of Co. The outstanding amount of spent batteries makes them to a core of urban mining warranting special attention. Greener technologies for Co recovery are necessary to achieve sustainable development. As a result of these sourcing challenges, this study is devoted to reviewing the techniques for Co recovery, such as acid leaching (inorganic and organic), separation (solvent extraction, ion exchange resins, and precipitation), and emerging technologies—ionic liquids, deep eutectic solvent, supercritical fluids, nanotechnology, and biohydrometallurgy. A dearth of research in emerging technologies for Co recovery from Li-ion batteries is discussed throughout the manuscript within a broader overview. The study is strictly connected to the Sustainability Development Goals (SDG) number 7, 8, 9, and 12.

Recovery of Platinum Group Metals from Spent Automotive Catalysts Using Lithium Salts and Hydrochloric Acid

The recovery of platinum group metals (PGMs) from waste materials involves dissolving the waste in an aqueous solution. However, since PGMs are precious metals, their dissolution requires strong oxidizing agents such as chlorine gas and aqua regia. In this study, we aimed to recover PGMs via the calcination of spent automotive catalysts (autocatalysts) with Li salts based on the concept of "spent autocatalyst + waste lithium-ion batteries" and leaching with only HCl. The results suggest that, when Li₂CO₃ was used, the Pt content was fully leached, while 94.9% and 97.5% of Rh and Pd, respectively, were leached using HCl addition. Even when LiF, which is a decomposition product of the electrolytic solution (LiPF₆), was used as the Li salt model, the PGM leaching rate did not significantly change. In addition, we studied the immobilization of fluorine on cordierite (2MgO·2Al₂O₃·5SiO₂), which is a matrix component of autocatalysts. Through the calcination of LiF in the presence of cordierite, we found that cordierite thermally decomposed, and fluorine was immobilized as MgF₂.

Separation of cathode particles and aluminum current foil in Lithium-Ion battery by high-voltage pulsed discharge Part I: Experimental investigation

To enable effective reuse and recycling processes of spent lithium-ion batteries (LiBs), here we develop a novel electrical method based on a high-voltage pulsed discharge to separate cathode particles and aluminum (Al) foil. A cathode particle sample was mechanically separated from a LiB, cut into 30-mm × 80-mm test pieces, and subjected to a high-voltage electrical pulse discharge from either end in water. At a voltage of 25 kV, 93.9% of the cathode particles separated from the Al foil. These particles were easily recovered by sieving at 2.36 mm because the Al foil retained its shape. Some Al contaminated the particles owing to generation of hot plasma and subsequent shock waves; however, the Al concentration in the recovered cathode particles was limited to 2.95%, which is low enough to allow for further cobalt and nickel recovery by hydrometallurgical processing. The results of heat balance calculations obtained from the current waveforms suggested that polyvinylidene fluoride, the main component of the adhesive in the cathode particle layers, melted and lost its adhesion through Joule heating of the Al foil at the maximum current of 19.0 kA at 25 kV. Almost 99% of the recovered cathode particles maintained their chemical composition and form after separation, and therefore could potentially be directly reused in LiBs.

Potential impact of the end-of-life batteries recycling of electric vehicles on lithium demand in China: 2010-2050

China is expected to realise the complete electrification of traditional internal combustion engine vehicles (ICEVs) by 2050. The rapid development of electric vehicles (EVs) has led to the continuous growth of traction lithium-ion battery (LIB) demand, leading to an increase in demand for specific lithium materials. Therefore, end-of-life (EoL) LIB recycling will largely determine the future lithium availability in China. However, the contribution of recovered lithium to lithium availability is unclear, as the possibility of recovering lithium for reuse in traction LIBs manufacturing is uncertain. To analyse the influence of recovered lithium quality on future lithium availability, we evaluated the potential impact of EoL LIB recycling on lithium demand in China. The results indicated that if new LIB manufacturing cannot use the recovered lithium; the secondary resources would soon exceed the needs of the basic demand (BD) field. In the optimistic scenario, when a LiS battery is used, the oversupply could reach 2.33 Mt by 2050 with a recovery rate of 80%, which is equivalent to 44.05% of China's current lithium reserves of 5.29 Mt. Additionally, when the NCM-G battery is used, the total lithium demand would reach approximately 5.67 Mt in 2031, exceeding China's current lithium reserves. In contrast, if the recovered lithium could be reused in new LIB manufacturing, regardless of the type of LIBs used, the recovered lithium would meet approximately 60% (pessimistic scenario), 53% (neutral scenario), and 49% (optimistic scenario) of the lithium demand for LIBs produced with a recovery rate of 80% by 2050. Consequently, the quality of recovered lithium is very important for its reuse, and it is necessary to develop closed-loop recycling with economic benefits vigorously by improving the quality of recovered lithium. Moreover, much work should be done in recycling infrastructure and industrial policies to promote EoL battery recycling.

The COOL-Process—A Selective Approach for Recycling Lithium Batteries

The global market of lithium-ion batteries (LIB) has been growing in recent years, mainly owed to electromobility. The global LIB market is forecasted to amount to $129.3 billion in 2027. Considering the global reserves needed to produce these batteries and their limited lifetime, efficient recycling processes for secondary sources are mandatory. A selective process for Li recycling from LIB black mass is described. Depending on the process parameters Li was recovered almost quantitatively by the COOL-Process making use of the selective leaching properties of supercritical CO2/water. Optimization of this direct carbonization process was carried out by a design of experiments (DOE) using a 33 Box-Behnken design. Optimal reaction conditions were 230 °C, 4 h, and a water:black mass ratio of 90 mL/g, yielding 98.6 ± 0.19 wt.% Li. Almost quantitative yield (99.05 ± 0.64 wt.%), yet at the expense of higher energy consumption, was obtained with 230 °C, 4 h, and a water:black mass ratio of 120 mL/g. Mainly Li and Al were mobilized, which allows for selectively precipitating Li2CO3 in battery grade-quality (>99.8 wt.%) without the need for further refining. Valuable metals, such as Co, Cu, Fe, Ni, and Mn, remained in the solid residue (97.7 wt.%), from where they are recovered by established processes. Housing materials were separated mechanically, thus recycling LIB without residues. This holistic zero waste-approach allows for recovering the critical raw material Li from both primary and secondary sources.

Recycling of LiCoO2 cathode material from spent lithium ion batteries by ultrasonic enhanced leaching and one-step regeneration

A novel process for recycling of spent LiCoO₂ cathode materials has been developed. The novel process comprises an ultrasonic enhanced leaching and one-step regeneration of LiCoO₂ materials with spray drying method. The ultrasonic is novelly applied for effectively improving leaching process of spent LiCoO₂ materials in the system of DL-malic acid and H₂O₂. The leaching efficiencies of 98.13% for Li and 98.86% for Co were presented under the optimal condition of 1.5 mol/L DL-malic acid with 3 vol% H₂O₂, the solid/liquid ratio of 4 g/L, ultrasonic power of 95 W, temperature of 80 °C and leaching time of 25 min. Based on kinetic analysis, the ultrasonic enhanced leaching process is mainly controlled by the diffusion control model. Meanwhile, the product of Co(C₄O₅O₅)₂ formed on particles surface of spent LiCoO₂ materials during ultrasonic enhanced leaching process, which is provided from reaction mechanism analysis of scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FT-IR) and X-ray photoelectron spectroscopy (XPS). Finally, the regenerated LiCoO₂ materials are regenerated in one step by spray drying from leaching solution, which present good electrochemical performance.

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

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

Investigation of the Physico-Chemical Properties of the Products Obtained after Mixed Organic-Inorganic Leaching of Spent Li-Ion Batteries

Lithium-ion batteries are currently one of the most important mobile energy storage units for portable electronics such as laptops, tablets, smartphones, etc. Their widespread application leads to the generation of large amounts of waste, so their recycling plays an important role in environmental policy. In this work, the process of leaching with sulfuric acid for the recovery of metals from spent Li-ion batteries in the presence of glutaric acid and hydrogen peroxide as reducing agents is presented. Experimental results indicate that glutaric-acid application improves the leaching performance compared to the use of just hydrogen peroxide under the same conditions. Obtained samples of leaching residues after mixed inorganic-organic leaching were characterized with Scanning Electron Microscopy, Fourier Transform Infrared Spectroscopy, and X-ray diffraction.

Efficient Direct Recycling of Degraded LiMn2O4 Cathodes by One-Step Hydrothermal Relithiation

Due to the large demand of lithium-ion batteries (LIBs) for energy storage in daily life and the limited lifetime of commercial LIB cells, exploring green and sustainable recycling methods becomes an urgent need to mitigate the environmental and economic issues associated with waste LIBs. In this work, we demonstrate an efficient direct recycling method to regenerate degraded lithium manganese oxide (LMO) cathodes to restore their high capacity, long cycling stability, and high rate performance, on par with pristine LMO materials. This one-step regeneration, achieved by a hydrothermal reaction in dilution Li-containing solution, enables the reconstruction of desired stoichiometry and microphase purity, which is further validated by testing spent LIBs with different states of health. Life-cycle analysis suggested the great environmental and economic benefits enabled by this direct regeneration method compared with today's pyro- and hydrometallurgical processes. This work not only represents a fundamental understanding of the relithiation mechanism of spent cathodes but also provides a potential solution for sustainable and closed-loop recycling and remanufacturing of energy materials.

Recovery of Co, Li, and Ni from Spent Li-Ion Batteries by the Inorganic and/or Organic Reducer Assisted Leaching Method

The battery powder (anodic and cathodic mass) manually separated from spent Li-ion batteries used in laptops was subjected to acidic reductive leaching to recover the Co, Li, and Ni contained in it. In the laboratory experiments, 1.5 M sulfuric acid was used as the leaching agent and the reducing agents were 30% H2O2 solution or/and glutaric acid. Glutaric acid is a potential new reducing agent in the leaching process of spent lithium-ion batteries (LIBs). The influence of the type of the used reducer on obtained recovery degrees of Co, Li, and Ni as well as the synergism of the two tested reducing compounds were analyzed. As a result, it was determined that it is possible to efficiently hydrometallurgically separate Co, Li, and Ni from battery powder into solutions. The highest recovery degrees of the investigated metals (Co: 87.85%; Li: 99.91%; Ni: 91.46%) were obtained for samples where two reducers, perhydrol and glutaric acid, were added, thus confirming the assumed synergic action of H2O2 and C5H8O4 in a given reaction environment.

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.

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.

Extraction of Co and Li2CO3 from cathode materials of spent lithium-ion batteries through a combined acid-leaching and electro-deoxidation approach

Recycling of the spent LIBs to extract Li and Co not only offers raw materials for batteries but also lays a sustainable way for battery development. Herein, we adopt a route combining hydrometallurgical and pyro-electrochemical routes to extract Li₂CO₃ and Co powder from the spent LIBs of cell phones. The LiCoO₂-based cathode materials were firstly dissolved in H₂SO₄ solution containing H₂O₂ as the reductant, and the optimal conditions for attaining a high extraction rate of 99% were studied. After that, the precipitated Co(OH)₂ was calcinated in air under 500 °C to generate Co₃O₄ which was thereafter electrochemically converted into Co powder and oxygen in molten Na₂CO₃-K₂CO₃. Overall, the hybrid method employing both hydro- and pyro-route provides an effective pathway to recover both Li₂CO₃ and Co powder from spent LIBs.

Effect of electrolyte reuse on metal recovery from waste CPU slots by slurry electrolysis

As an indispensable part of printed circuit boards (PCBs), central processing unit (CPU) slots contain a significant amount of precious metals which makes economic sense to recycle these materials. Slurry electrolysis is an attractive approach for electronic waste (e-waste) recycling. In this study, the effect of electrolyte reuse on the recovery of metals (Primarily aluminum, nickel, copper, lead, silver, palladium, platinum and gold), from waste CPU slots by slurry electrolysis is discussed in detail. These results show that metal recovery rate, more than 95% for all 13 cycles, was not affected by slurry electrolyte reuse during metal recycling from waste CPU slots, though the reuse of slurry electrolyte greatly impacted the distribution of metals in the anode residues, electrolyte and cathode metal powders. However, slurry electrolysis recovered metals from waste CPU slots and the effect of electrolyte reuse on the recovery of metals from waste CPU slots is discussed for the first time in this study. This could benefit the recycling process since it could improve cathode metal powders recovery rates by approximately 2 times. The acid usage could be significantly reduced by electrolyte reuse when compared to fresh electrolyte. Therefore, electrolyte reuse is demonstrated and slurry electrolysis is a feasible and potentially economically friendly choice for industrial e-waste recycling.

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.

Effect of Different Pressures on Microstructure and Mechanical Performance of F-III Fibers in Supercritical Carbon Dioxide Fluid

F-III fibers were treated at different pressures in supercritical carbon dioxide fluid and all samples including untreated and treated F-III fibers were characterized by a mechanical performance tester, wide-angle X-ray scattering and small-angle X-ray scattering. By studying the relationship between mechanical performance and microstructural changes of the samples, it was found that microstructural change was the main cause of variation in mechanical performance. Results revealed that the maximum tensile strength and modulus of F-III fibers were acquired at 14 MPa within the pressure range of 8 MPa to 16 MPa when the temperature, tension and time were 250 °C, 6 g·d⁻¹ and 40 min, respectively. Correspondingly, the microstructures of the samples, including the phase fraction, crystal size, orientation factor, fibril radius, fibril length and misorientation angle, have been investigated. It was fortunate that the supercritical carbon dioxide fluid could be used as a medium during the hot-stretch process to improve the mechanical performance of F-III fibers, although the treatment temperature was lower than the glass transition temperature of the F-III fibers.

Recovery of cobalt from dilute aqueous solutions using activated carbon–alginate composite spheres impregnated with Cyanex 272

Waste water was purified from cobalt(ii) and manganese(ii) by adsorption and desorption on shaped and impregnated activated carbon spheres.

Unveiling the Role and Mechanism of Mechanochemical Activation on Lithium Cobalt Oxide Powders from Spent Lithium-Ion Batteries

This research presented the impacts of mechanochemical activation (MCA) on the physiochemical properties of lithium cobalt oxide (LiCoO₂) powders of cathode materials from spent lithium-ion batteries, and analyzed the relevant effects of these changes on the leaching efficiency of lithium and cobalt and the leaching kinetics of LiCoO₂ powders. The results revealed the superiority of MCA in the following levels of changes in the LiCoO₂ powders: first, the physical properties included a decrease in the average particle size, an increase in the specific surface area, and the appearance of a mesoporous structure change; second, changes in crystal-phase structures were reflected in the grain refinement of LiCoO₂ powders, lattice distortions, lattice dislocations, and storage and increment of internal energy; third, the surface characteristics included a chemical shift of lithium element electrons, a reduction in Co³⁺ concentration, and an increment in the surface hydroxyl oxygen concentration. These changes in physiochemical properties and structures enhanced the hydrophilicity and interface reactivity of the activated LiCoO₂ powders and significantly improved the leaching efficiencies of Li and Co in organic acid solutions. The rate-limiting step of metal leaching was also altered from a surface chemical reaction-controlled one before MCA to an ash layer diffusion-controlled one after MCA.

Leaching kinetics of cobalt from the scraps of spent aerospace magnetic materials

Based on physicochemical properties of the scraps of spent aerospace magnetic materials, a roasting - magnetic separation followed by sulfuric acid leaching process was proposed to extract cobalt. Roasting was performed at 500 °C to remove organic impurity. Non-magnetic impurities were reduced by magnetic separation and then the raw material was sieved into desired particle sizes. Acid leaching was carried out to extract cobalt from the scraps and experimental parameters included agitation speed, particle size, initial concentration of sulfuric acid and temperature. Agitation speed higher than 300 r/min had a relatively small impact on the cobalt extraction. As the particle size reduced, the content of cobalt in the raw material decreases and the extraction of cobalt by acid leaching increased at first and decreased afterwards. Raising the initial concentration of sulfuric acid and temperature contributed to improve the cobalt extraction and the influence of temperature was more remarkable. SEM image revealed that the spent aerospace magnetic materials mainly existed in the sliced strip flake with a loose surface and porous structure. Under the experimental condition, the leaching rate of cobalt from the scraps in sulfuric acid solution could be expressed as ln(-ln(1 - α)) = lnk + nlnt. The apparent activation energy was found to be 38.33 kJ/mol and it was mainly controlled by the surface chemical reaction.

Comprehensive evaluation on effective leaching of critical metals from spent lithium-ion batteries

Recovery of metals from spent lithium-ion batteries (LIBs) has attracted worldwide attention because of issues from both environmental impacts and resource supply. Leaching, for instance using an acidic solution, is a critical step for effective recovery of metals from spent LIBs. To achieve both high leaching efficiency and selectivity of the targeted metals, improved understanding on the interactive features of the materials and leaching solutions is highly required. However, such understanding is still limited at least caused by the variation on physiochemical properties of different leaching solutions. In this research, a comprehensive investigation and evaluation on the leaching process using acidic solutions to recycle spent LIBs is carried out. Through analyzing two important parameters, i.e. leaching speed and recovery rate of the corresponding metals, the effects of hydrogen ion concentration, acid species and concentration on these two parameters were evaluated. It was found that a leachant with organic acids may leach Co and Li from the cathode scrap and leave Al foil as metallic form with high leaching selectivity, while that with inorganic acids typically leach all metals into the solution. Inconsistency between the leaching selectivity and efficiency during spent LIBs recycling is frequently noticed. In order to achieve an optimal status with both high leaching selectivity and efficiency (especially at high solid-to-liquid ratios), it is important to manipulate the average leaching speed and recovery rate of metals to optimize the leaching conditions. Subsequently, it is found that the leaching speed is significantly dependent on the hydrogen ion concentration and the capability of releasing hydrogen ions of the acidic leachant during leaching. With this research, it is expected to improve understanding on controlling the physiochemical properties of a leaching solution and to potentially design processes for spent LIBs recycling with high industrial viability.

Toward sustainable and systematic recycling of spent rechargeable batteries

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

A combined process for cobalt recovering and cathode material regeneration from spent LiCoO2 batteries: Process optimization and kinetics aspects

A combined process has been developed for recovering cobalt and regenerating cathode material from leach liquor of spent LiCoO₂ batteries. Cobalt of 98% can be selectively separated from leach liquor using ammonium oxalate of 1.15 (mole ratio) at pH of 2.0, 55 °C, and 40 min. Kinetics analysis indicates that precipitation of cobalt is controlled by a combination of surface chemical reaction and diffusion. The E_a value of precipitation is 19.68 kJ/mol obtained from the second-order model of (1 - a)^-1 = k't + c. Based on the TG/DSC curves of oxidation of cobalt oxalate, it is found that formation of Co₃O₄ oxidized from cobalt oxalate is in according with the model of randomly nucleating followed by nucleus growth. The E_a value is 84.93 kJ/mol that is provided by the suitable model of g(α) = [-ln(1 - α)]^1/3. Then, lithium is recovered from the filtrate as Li₂CO₃ with the purity of 99.5% by precipitation method. Finally, new cathode material with a good electrochemical performance is regenerated using obtained Co₃O₄ and lithium carbonate through solid phase method.

Hydrometallurgical recycling of lithium-ion batteries by reductive leaching with sodium metabisulphite

The hydrometallurgical extraction of metals from spent lithium-ion batteries (LIBs) was investigated. LIBs were first dismantled and a fraction rich in the active material was obtained by physical separation, containing 95% of the initial electrode, 2% of the initial steel and 22% of plastic materials. Several reducers were tested to improve metals dissolution in the leaching step using sulphuric acid. Sodium metabisulphite led to the best results and was studied in more detail. The best concentration of Na₂S₂O₅ was 0.1 M. The metals dissolution increased with acid concentration, however, concentrations higher than 1.25 M are unnecessary. Best results were reached using a stirring speed of 400 min^-1. The metals leaching efficiency from the active material (Li, Mn, Ni, Co) increased with the temperature and was above 80% for temperatures higher than 60 °C. The dissolution of metals also rose with the increase in the liquid/solid ratio (L/S), however, extractions above 85% can be reached at L/S as lower as 4.5 L/kg, which is favourable for further purification and recovery operations. About 90% of metals extraction can be achieved after only 0.5 h of leaching. Sodium metabisulphite can be an alternative reducer to increase the leaching of Li, Mn, Co, and Ni from spent LIBs.