Recovery of valuable metals from mixed types of spent lithium ion batteries. Part II: Selective extraction of lithium

Study on green closed-loop regeneration of waste lithium iron phosphate based on oxalic acid system

The recovery of valuable metals from used lithium batteries is essential from an environmental and resource management standpoint. However, the most widely used acid leaching method causes significant ecological harm. Here, we proposed a method of recovering Li and Fe selectively from used lithium iron phosphate batteries by using low-concentration organic acid and completing the closed-loop regeneration. Low-concentration oxalic acid is used to carry out PO43-, which is significantly less soluble in aqueous solution than Li, two-stage selective leaching Li, where the leaching rate of Li reaches 99 %, and the leaching rate of Fe is only 2.4 %. The leach solution is then decontaminated. The solubility of Li3PO4 in aqueous solution is much smaller than that of Li2C2O4, which was required to recover Li to change the pH and Li can be recovered as Li3PO4; Fe can be retrieved as FeC2O4·2H2O, and re-prepared into lithium iron phosphate.

High-Selectivity Recycling of Valuable Metals from Spent Lithium-Ion Batteries Using Recyclable Deep Eutectic Solvents

The recovery of valuable metals from spent lithium-ion batteries using deep eutectic solvents (DESs) is an environmentally and economically beneficial process. In this study, a method has been developed for recovering LiNi0.33Co0.33Mn0.33O2. Our process operates under mild conditions and with a little oxalic acid as a reducing agent, dissolving lithium, cobalt, manganese, and nickel completely utilizing a DES that is composed of tetrabutylammonium chloride and of monochloroacetic acid. Lithium and nickel were selectively precipitated using oxalic acid. Cobalt and manganese were precipitated as oxalates by adding an oxalic acid aqueous solution. Finally, the DES can be regenerated by evaporating the water. Importantly, valuable metals can be recovered with a 100 % yield through the process of DES recycling. This environmentally friendly and recyclable process is suitable for the recycling of spent lithium-ion batteries industry.

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.

A review on the recycling of spent lithium iron phosphate batteries

Lithium iron phosphate (LFP) batteries have gained widespread recognition for their exceptional thermal stability, remarkable cycling performance, non-toxic attributes, and cost-effectiveness. However, the increased adoption of LFP batteries has led to a surge in spent LFP battery disposal. Improper handling of waste LFP batteries could result in adverse consequences, including environmental degradation and the mismanagement of valuable secondary resources. This paper presents a comprehensive examination of waste LFP battery treatment methods, encompassing a holistic analysis of their recycling impact across five dimensions: resources, energy, environment, economy, and society. The recycling of waste LFP batteries is not only crucial for reducing the environmental pollution caused by hazardous components but also enables the valuable components to be efficiently recycled, promoting resource utilization. This, in turn, benefits the sustainable development of the energy industry, contributes to economic gains, stimulates social development, and enhances employment rates. Therefore, the recycling of discarded LFP batteries is both essential and inevitable. In addition, the roles and responsibilities of various stakeholders, including governments, corporations, and communities, in the realm of waste LFP battery recycling are also scrutinized, underscoring their pivotal engagement and collaboration. Notably, this paper concentrates on surveying the current research status and technological advancements within the waste LFP battery lifecycle, and juxtaposes their respective merits and drawbacks, thus furnishing a comprehensive evaluation and foresight for future progress.

Probing Hybrid LiFePO4/FePO4 Phases in a Single Olive LiFePO4 Particle and Their Recovering from Degraded Electric Vehicle Batteries

The recycling of LiFePO4 from degraded lithium-ion batteries (LIBs) from electric vehicles (EVs) has gained significant attention due to resource, environment, and cost considerations. Through neutron diffraction, X-ray photoelectron spectroscopy, and transmission electron microscopy, we revealed continuous lithium loss during battery cycling, resulting in a Li-deficient state (Li1-xFePO4) and phase separation within individual particles, where olive-shaped FePO4 nanodomains (5-10 nm) were embedded in the LiFePO4 matrix. The preservation of the olive-shaped skeleton during Li loss and phase change enabled materials recovery. By chemical compensation for the lithium loss, we successfully restored the hybrid LiFePO4/FePO4 structure to pure LiFePO4, eliminating nanograin boundaries. The regenerated LiFePO4 (R-LiFePO4) exhibited a high crystallinity similar to the fresh counterpart. This study highlights the importance of topotactic chemical reactions in structural repair and offers insights into the potential of targeted Li compensation for energy-efficient recycling of battery electrode materials with polyanion-type skeletons.

Preparation and Performance of Regenerated Al2O3-Coated Cathode Material LiNi0.8Co0.15Al0.05O2 from Spent Power Lithium-Ion Batteries

In this study, LiNi_0.8Co_0.15Al_0.05O₂@x%Al₂O_3-coated cathode materials were regeneratively compounded by the solid-phase sintering method, and their structural characterization and electrochemical performance were systematically analyzed. The regenerated ternary cathode material precursor synthesized by the co-precipitation method was roasted with lithium carbonate at a molar ratio of 1:1.1, and then completely mixed with different contents of aluminum hydroxide. The combined materials were then sintered at 800 °C for 15 h to obtain the regenerated coated cathode material, LiNi_0.8Co_0.15Al_0.05O₂@x%Al₂O₃. The thermogravimetry analysis, phase composition, morphological characteristics, and other tests show that when the added content of aluminum hydroxide is 3%, the regenerated cathode material, LiNi_0.8Co_0.15Al_0.05O₂@1.5%Al₂O_3, exhibits the highest-order layered structure with Al₂O₃ coating. This material can better inhibit the production of Ni²⁺, and improve material structure and electrochemical properties. The first charge-discharge efficiency of the battery assembled with this regenerated cathode material is 97.4%, a 50-cycle capacity retention is 93.4%, and a 100-cycle capacity retention is 87.6%. The first charge-discharge efficiency is far better than that of the uncoated regenerated battery.

One-step selective separation and efficient recovery of valuable metals from mixed spent lithium batteries in the phosphoric acid system

The recovery of valuable elements in spent lithium-ion batteries (LIBs) has attracted more and more attention. Efficient recovery of valuable elements from spent LIBs with lower consumption and shorter process is the target that people have been pursuing. In this study, the valuable metals (Ni, Co, Mn and Li) and FePO₄ products are simultaneously recovered from mixed spent LiNi_xCo_yMn_zO₂ and LiFePO₄ in one step under the optimized condition of 0.88 M H₃PO₄, a mass ratio of LFP/NCM of 2:1, a L/S ratio of 33:1 and 80 ℃ for 120 min without additional auxiliary reagents. Over 60 % of acid consumption is reduced and the process of adjusting pH is avoidable. The leaching efficiencies of the valuable elements reach up to 99.1 % for Ni, 98.9 % for Co, 99.6 % for Li and 97.3 % for Mn. Almost all of Fe is precipitated as FePO₄·2H₂O. By means of the empirical model, the research on leaching kinetics demonstrates that the leaching reaction is internal diffusion-controlled with the apparent activation energy of valuable metals less than 30 kJ/mol. Furthermore, the redox reaction mechanism between spent LiBs has been explored. And the intrinsic driving force in the phosphoric acid system is found out. This finding may provide an innovative and selective recycling method for valuable elements from mixed spent LIBs with high economic benefit and fewer environmental footprints.

Applications of crushing and grinding-based treatments for typical metal-containing solid wastes: Detoxification and resource recovery potentials

Metal-containing solid wastes can induce serious environmental pollution if managed improperly, but contain considerable resources. The detoxification and resource recoveries of these wastes are of both environmental and economic significances, being indispensable for circular economy. In the past decades, attempts have been made worldwide to treat these wastes. Crushing and grinding-based treatments have been increasingly applied, the operating apparatus and parameters of which depend on the waste type and treatment purpose. Based on the relevant studies, the applications of crushing and grinding on four major types of solid wastes, namely spent lithium-ion batteries (LIBs) cathode, waste printed circuit boards (WPCBs), incineration bottom ash (IBA), and incineration fly ash (IFA) are here systematically reviewed. These types of solid wastes are generated in increasing amounts, and have the potentials to release various organic and inorganic pollutants. Despite of the widely different texture, composition, and other physicochemical properties of the solid wastes, crushing and grinding have been demonstrated to be universally applicable. For each of the four wastes, the technical route that involving crushing and grinding is described with the advantages highlighted. The crushing and grinding serve either mainstream or auxiliary role in the processing of the solid wastes. This review summarizes and highlights the developments and future directions of crushing and grinding-based treatments.

A sustainable closed-loop method of selective oxidation leaching and regeneration for lithium iron phosphate cathode materials from spent batteries

A sustainable closed-loop method for recovering waste lithium iron phosphate batteries is developed in this paper. Li⁺ was selectively leached from cathode materials in a system of NaHSO₄ and H₂O₂. Under the optimal conditions of leaching temperature of 65 °C, 1.1 times molar quantity NaHSO₄, 2 vol% H₂O₂, solid-liquid ratio of 100 g/L and leaching time of 15 min, the leaching efficiency of Li can reach 99.84%, while Fe is only 0.048%. Meanwhile, XRD, FTIR, XPS and TEM analysis were carried out to explore the conversion mechanism in the oxidation leaching process of the original raw and leaching products. Li⁺ in the filtrate was precipitated with Na₂CO₃ and converted into Li₂CO₃. The precipitated salty wastewater can be converted into leaching agent for recycling by adding a certain amount of sulfuric acid. The recycled products are used to synthesize LiFePO₄ materials, and regenerated LiFePO₄ materials show good electrochemical properties. The discharge capacity displays 141.3 mAhg^-1 at 1C, with the capacity retention rate of 99.4% after 200 cycles. This study provides a sustainable closed-loop process for recycling and reuse of waste LiFePO₄ batteries, which promotes resource conservation and environmental protection.

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.

Preferential Extraction of Lithium from Spent Cathodes and the Regeneration of Layered Oxides for Li/Na-Ion Batteries

The preferentially selective extraction of Li⁺ from spent layered transition metal oxide (LiMO₂, M = Ni, Co, Mn, etc.) cathodes has attracted extensive interest based on economic and recycling efficiency requirements. Presently, the efficient recycling of spent LiMO₂ is still challenging due to the element loss in multistep processes. Here, we developed a facile strategy to selectively extract Li⁺ from LiMO₂ scraps with stoichiometric H₂SO₄. The proton exchange reaction could be driven using temperature, accompanied by the generation of soluble Li₂SO₄ and MOOH precipitates. The extraction mechanism includes a two-stage evolution, including dissolution and ion exchange. As a result, the extraction rate of Li⁺ is over 98.5% and that of M ions is less than 0.1% for S-NCM. For S-LCO, the selective extraction result is even better. Finally, Li₂CO₃ products with a purity of 99.68% can be prepared from the Li⁺-rich leachate, demonstrating lithium recovery efficiencies as high as 95 and 96.3% from NCM scraps and S-LCO scraps, respectively. In the available cases, this work also represents the highest recycling efficiency of lithium, which can be attributed to the high leaching rate and selectivity of Li⁺, and even demonstrates the lowest reagent cost. The regenerated LiNi_0.5Co_0.24Mn_0.26O₂ and Na_1.01Li_0.001Ni_0.38Co_0.18Mn_0.44O₂ cathodes also deliver a decent electrochemical performance for Li-ion batteries (LIBs) and Na-ion batteries (NIBs), respectively. Our current work offers a facile, closed-loop, and scalable strategy for recycling spent LIB cathodes based on the preferentially selective extraction of Li⁺, which is superior to the other leaching technology in terms of its cost and recycling yield.

Recovery of Lithium Iron Phosphate by Specific Ultrasonic Cavitation Parameters

With the widespread use of lithium iron phosphate batteries in various industries, the amount of waste lithium iron phosphate batteries is also increasing year by year, and if not disposed of in a timely manner, will pollute the environment and waste a lot of metal resources. In the composition of lithium iron phosphate batteries, the cathode has an abundance of elements. The ultrasonic method is a crucial method to recover waste LiFePO4 batteries. It has the following disadvantages, such as the lack of empirical parameters and suitable research equipment. In order to overcome the inefficiency of the LiFePO4 recycling method, the airborne bubble dynamical mechanism of ultrasound in the removal of lithium phosphate cathode material was studied by a high-speed photographic observation and Fluent simulation and the disengagement process. Mainly aimed at the parameters such as action time, power, frequency, and action position in the detachment process were optimized. The recovery efficiency of lithium iron phosphate reached 77.7%, and the recovered lithium iron phosphate powder has good electrochemical properties, with the first charge–discharge ratio of up to 145 (mAh)/g. It is shown that the new disengagement process established in this study was adopted for the recovery of waste LiFePO4.

A Novel Recycling Route for Spent Li-Ion Batteries

In this work, a recycling route for spent Li-ion batteries (LIBs) was developed. For this, the recovery of the metal content in both electrodes (anode and cathode) was investigated. Based on these results, an economic analysis of this recycling process was carried out. The obtained results showed that more than 90% of the material contained in both electrodes was recycled. The dissolution with acetic acid of the metals present in the active cathodic material is thermodynamically viable and the addition of a reducing agent such as hydrogen peroxide improved the spontaneity of the reaction. Dissolutions close to 100% for Li and Co were obtained. In addition, it was determined that the synthesis of lithium and cobalt valuable compounds was viable from the leach liquor, recovering approximately 90% of Co as cobalt oxalate, and 92% of Li as lithium carbonate. Furthermore, carbon graphite and Cu were fully recovered (100%) from the anodes. Finally, the results of the economic analysis showed that the recovered products have a high commercial value and industrial interest, providing an environmentally and economically viable process.

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.

Novel electrochemically driven and internal circulation process for valuable metals recycling from spent lithium-ion batteries

The sustainable recycling of valuable metals from spent lithium-ion batteries (LIBs) is impeded by the issues of extensive chemicals consumption, tedious separation process and deficient selectivity. Here, novel electrochemically driven and internal circulation strategy was developed for the direct and selective recycling of valuable metals from waste LiCoO₂ of spent LIBs. Firstly, the waste LiCoO₂ can be efficiently dissolved by generated acid (H₂SO₄) during electro-deposition of Cu from CuSO₄ electrolyte. Then, Co²⁺ ions in the lixivium can be electrodeposited and recovered as metallic Co with a coinstantaneous regeneration of H₂SO₄ and regenerated acid can be reused as leachant without obvious shrinking of leaching capability based on circulating leaching results. Over 92% Co and 97% Li can be leached, and 100% Cu and 93% Co are recovered as their metallic forms under the optimized experimental conditions. Results of leaching kinetics suggest that the leaching of Co and Li is controlled by internal diffusion with significantly reduced apparent activation energies (E_a) for Li and Co. Finally, Li₂CO₃ can be recovered from Li⁺ enriched lixivium after circulating leaching. This recycling process is a simplified route without any input of leachant and reductant, and valuable metals can be selectively recovered in a closed-loop way with high efficiency.

Recycling of LiFePO4 cathode materials from spent lithium-ion batteries through ultrasound-assisted Fenton reaction and lithium compensation

Efficient exfoliation of cathode materials from current collectors for their direct regeneration is the typical bottleneck during spent lithium ion batteries (LIBs) recycling due to the strong adhesion of PVDF (polyvinylidene fluoride) binders. Ultrasound-assisted Fenton reaction was innovatively applied for the selective removal of PVDF binders to recover cathode materials of LiFePO₄ from current collectors and the recovered LiFePO₄ was regenerated through lithium compensation, targeting for the in-situ recycling of cathode materials from spent LIBs. Experimental results suggest that the PVDF binders were adequately degraded by hydroxyl radical (·OH) generated from Fenton's reagent with reinforcement of ultrasound, and about 97% cathode materials can be scrubbed from Al foils under optimized conditions. Detailed analytical results support that the cathode materials peeled off from current collectors are free from contamination of effluent, and the recovered LiFePO₄ can be directly re-fabricated as new cathode materials through lithium compensation with little reduction of electrochemical performances. And the tentative mechanism investigation for pathway of ·OH generation and chemical reactions indicates that ·OH generated from Fenton's reagent with the reinforcement of ultrasound can effectively degrade PVDF binders. This work can be a green and efficient candidate for the in-situ recycling of cathode materials of LiFePO₄ from spent LIBs.

Oxidizing Roasting Behavior and Leaching Performance for the Recovery of Spent LiFePO4 Batteries

In this study, the effects of oxidizing roasting process on the liberation of cathode materials from Al foil under different conditions were investigated systematically. The mineralogical characteristics of the cathode materials before and after thermal treatment were extensively characterized using scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), X-ray diffraction (XRD) as well as Fourier transform infrared (FT-IR) spectroscopy and X-ray photoelectron spectroscopy (XPS). The results indicated that the increase in roasting temperature, oxygen concentration, and air flow rate enhanced the liberation of cathode materials. The cathode materials were gradually oxidized to Li3Fe2(PO4)3 and Fe2O3. Further, the carbon and fluorine content in the cathode materials decreased slowly during the thermal treatment, while the Al content increased. When the roasting temperature exceeded the melting point of Al, the Al foils were ablated and the cathode materials adhered to the Al foils again, resulting in difficulty in separation. The cathode materials leaching performance test results demonstrated that the oxidation of cathode materials had a negative effect on the leaching of Fe in sulfuric acid leaching system.

Efficient process for recovery of waste LiMn2O4 cathode material precipitation thermodynamic analysis and separation experiments

An efficient process is proposed for recovery of waste LiMn₂O₄ cathode material, which is one of the most commonly used cathode materials in LIBs. This report constitutes the precipitation thermodynamic analysis and separation experiments based on the water-leaching solutions during the processes of low-temperature calcination with (NH₄)₂SO₄ and water-leaching. Precipitation thermodynamic analysis is undertaken to investigate the effects of initial concentration of the target solution, [N]_T1, excess precipitant, and addition of (NH₄)₂SO₄ on the manganese precipitation in the Mn²⁺-Li⁺-SO₄^2--NH₃-NH₄⁺-CO₃^2--H₂O system. Moreover, the effects of initial concentration of the target solution, [N]_T2, and excess precipitant on the lithium precipitation in the Li⁺-SO₄^2--NH₃-NH₄⁺-CO₃^2--H₂O system are investigated. All these factors clearly influence the manganese and lithium precipitation, particularly the [N]_T and the presence of excess precipitant in the system. The precipitation experimental results demonstrate that the optimal conditions are: a precipitation temperature of 35 °C; an excess coefficient of the precipitant of 2.4; the use of NHC-3 to precipitate the ML-3 solution; a maximum precipitation percentage of manganese of 99.96%; and an absence of Li₂CO₃ precipitation. The double-sulfate salts (Li(NH₄)SO₄ & (NH₄)₂SO₄) evaporated and crystallised from the Li⁺/NH₄⁺ solution are mixed with the waste LiMn₂O₄ cathode material for calcination and water leaching, for which the efficiencies of Li and Mn are 100% and 96.89%, respectively. The double-sulfate salts are calcined at 550 °C for 45 min to obtain the Li₂SO₄ product. Finally, the complete recovery and separation of Mn and Li in the waste LiMn₂O₄ cathode material are achieved.

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

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

Direct regeneration of spent LiFePO4via a graphite prelithiation strategy

A new, low-cost and green regeneration method was developed to revive spent LiFePO₄-based batteries.

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.

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

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

Acid-Free and Selective Extraction of Lithium from Spent Lithium Iron Phosphate Batteries via a Mechanochemically Induced Isomorphic Substitution

Lithium (Li) is the most valuable metal in spent lithium iron phosphate (LiFePO₄) batteries, but its recovery has become a challenge in electronic waste recovery because of its relatively low content and inconsistent quality. This study proposes an acid-free and selective Li extraction process to successfully achieve the isomorphic substitution of Li in LiFePO₄ crystals with sodium (Na). The method uses low-cost and nontoxic sodium chloride (NaCl) as a cogrinding reagent via a mechanical force-induced solid-phase reaction. X-ray diffraction (XRD), energy dispersive X-ray analysis (EDAX), and X-ray photoelectron spectroscopy (XPS) characterizations demonstrated the evidence of Li/Na isomorphic substitution, while XPS spectra of Fe 2p, P 2p, and O 1s revealed that the coordination environment of these elements was not significantly altered. Density functional theory calculations further provided evidence that Na and Li share similar outer electron arrangements and coordination environments, favoring Na over Fe as a replacement for Li in LiFePO₄. Additionally, the regeneration of NaCl and the recovery of precipitated Li₂CO₃ were simultaneously achieved with Na₂CO₃ as the sole reagent. This concise and efficient acid-free mechanochemical process for Li extraction is a promising candidate for feasible recycling technology of Li from spent LiFePO₄ batteries. The proposed process is particularly appealing because of its high selectivity, considerable economic advantages, and environmental benefits.

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.

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.