Improved recovery of valuable metals from spent lithium-ion batteries by efficient reduction roasting and facile acid leaching

Improved recovery of lithium from spent lithium-ion batteries by reduction roasting and NaHCO3 leaching

Lithium supply risk is increasing and driving rapid progress in lithium recovery schemes from spent lithium-ion batteries (LIBs). In this study, a facile recycling process consisting mainly of reduction roasting and NaHCO3 leaching was adopted to improve lithium recovery. The Li of spent LiNixCoyMn1-x-yO2 powder were converted to Li2CO3 and LiAlO2 with the reduction effect of C and residual Al in the roasting process. NaHCO3 leaching was utilized to selectively dissolve lithium from Li2CO3 and water-insoluble LiAlO2. The activation energy of NaHCO3 leaching was 9.31 kJ∙mol-1 and the leaching of lithium was a diffusion control reaction. More than 95.19 % lithium was leached and recovered as a Li2CO3 product with a purity of 99.80 %. Thus, this approach provides a green path to selective recovery of lithium with good economics.

Selective recovery of manganese from spent ternary lithium-ion batteries for efficient catalytic oxidation of VOCs: Unveiling the mechanism of activity Enhancement in recycled catalysts

With the widespread application of ternary lithium-ion batteries (TLBs) in various fields, the disposal of spent TLBs has become a globally recognized issue. This study proposes a novel method for reutilizing metal resources from TLBs. Through selective oxidation, manganese in a leaching solution of TLBs was converted into MnO2 with α, γ, and δ crystal phases (referred to as T-MnO2) for catalytic oxidation of volatile organic compounds (VOCs), while efficiently separating manganese from high-value metals such as nickel, cobalt, and lithium, achieving a manganese recovery rate of 99.99%. Compared to similar MnO2 prepared from pure materials, T-MnO2 exhibited superior degradation performance for toluene and chlorobenzene, with T90 decreasing by around 30 °C. The acidic synthesis environment provided by the leaching solution and the doping of trace metals altered the physicochemical properties of T-MnO2, such as increased specific surface area, elevated surface manganese valence, and improved redox performance and oxygen vacancy properties, enhancing its catalytic oxidation capacity. Furthermore, the degradation pathway of toluene on T-γ-MnO2 was inferred using thermal desorption-gas chromatography/mass spectrometry (TD-GC/MS) and in-situ DRIFTs. This study provides a novel approach for recycling spent TLBs and treating VOCs catalytically.

Efficient Regeneration of Graphite from Spent Lithium-Ion Batteries through Combination of Thermal and Wet Metallurgical Approaches

With the large-scale application of lithium-ion batteries (LIBs) in various fields, spent LIBs are considered one of the most important secondary resources. Few studies have focused on recycling anode materials despite their high value. Herein, a new efficient recycling and regeneration method of spent anode materials through the combination of thermal and wet metallurgical approaches and restored graphite performance is presented. Using this method, the lithium recycling ratio from spent anode materials reaches 87%, with no metal impurities detected in the leaching solution. The initial Coulombic efficiency of the recycled graphite (RG) materials is 90.5%, with a reversible capacity of 350.2 mAh/g. Moreover, RG shows better rate performance than commercial graphite. The proposed method is simple and efficient and does not involve toxic substances. Thus, it has high economic value and application potential in graphite recycling from spent LIBs.

Cleaner separation and recovery of valuable metals from spent ternary cathode via carbon dioxide synergetic thermite reduction strategy

The low-carbon recycling of spent lithium-ion batteries has become crucial due to the increasing need to address resource shortages and environmental concerns. Herein, a low-carbon, facile, and efficient method was developed to separate and recover Li, Al, and transition metals from spent ternary cathodes. Initially, the cathode materials post-discharge and disassembly do not require pre-sorting. Instead of using carbonaceous materials, the Al foil in the cathode serves as the reducing agent during reduction roasting. The impact of different roasting atmospheres (air, N2, CO2) on phase transitions and the extraction of valuable metals was examined. The findings revealed that after synergistic thermite reduction in a carbon dioxide atmosphere, the cathode material is completely dissociated. Li is selectively converted to Li2CO3 rather than LiAlO2, and the reduced reactivity of the Al foil encourages the formation of lower-valence oxides of Ni and Co, rather than their metallic forms. Under optimal roasting conditions at 650 °C for 1.0 h, 91.4% of Li can be preferentially and selectively extracted through carbonation water leaching, with less than 0.1% of Al and transition metals dissolving. Subsequently, ∼98% of Al and ∼99% of Ni, Co, and Mn can be leached using alkaline and acidic solutions, respectively. Compared to the traditional carbon thermal reduction process, this process offers several advantages including the elimination of pre-sorting and additional reducing agents, lower carbon emissions, and higher recovery rates of valuable metals. Thus, this process makes the recovery of metals from spent lithium-ion batteries more environmentally sustainable, simple, cost-effective, and adaptable.

Recycling and Reuse of Spent LIBs: Technological Advances and Future Directions

Recovering valuable metals from spent lithium-ion batteries (LIBs), a kind of solid waste with high pollution and high-value potential, is very important. In recent years, the extraction of valuable metals from the cathodes of spent LIBs and cathode regeneration technology are still rapidly developing (such as flash Joule heating technology to regenerate cathodes). This review summarized the studies published in the recent ten years to catch the rapid pace of development in this field. The development, structure, and working principle of LIBs were firstly introduced. Subsequently, the recent developments in mechanisms and processes of pyrometallurgy and hydrometallurgy for extracting valuable metals and cathode regeneration were summarized. The commonly used processes, products, and efficiencies for the recycling of nickel-cobalt-manganese cathodes (NCM/LCO/LMO/NCA) and lithium iron phosphate (LFP) cathodes were analyzed and compared. Compared with pyrometallurgy and hydrometallurgy, the regeneration method was a method with a higher resource utilization rate, which has more industrial application prospects. Finally, this paper pointed out the shortcomings of the current research and put forward some suggestions for the recovery and reuse of spent lithium-ion battery cathodes in the future.

Recycling and Reusing of Graphite from Retired Lithium-ion Batteries: A Review

The proliferation of rechargeable lithium-ion batteries (LIBs) over the past decade has led to a significant increase in the number of electric vehicles (EVs) powered by these batteries reaching the end of their lifespan. With retired EVs becoming more prevalent, recycling and reusing their components, particularly graphite, has become imperative as the world transitions toward electric mobility. Graphite constitutes ≈20% of LIBs by weight, making it a valuable resource to be conserved. This review presents an in-depth analysis of the current global graphite mining landscape and explores potential opportunities for the "second life" of graphitefrom depleted LIBs. Various recycling and reactivation technologies in both industry and academia are discussed, along with potential applications for recycled graphite forming a vital aspect of the waste management hierarchy. Furthermore, this review addresses the future challenges faced by the recycling industry in dealing with expired LIBs, encompassing environmental, economic, legal, and regulatory considerations. In conclusion, this review provides a comprehensive overview of the developments in recycling and reusing graphite from retired LIBs, offering valuable insights for forthcoming large-scale recycling efforts.

Recycling and reutilization of smelting dust as a secondary resource: A review

Smelting dust is a toxic waste produced in metal-mineral pyrometallurgical processes. To eliminate or reduce the adverse environmental impacts of smelting dust, valuable components need to be selectively separated from the toxic components present in the waste. This paper reviews the chemical composition, phase composition and particle size distribution characteristics of smelting dust, and the results show that smelting dust has excellent physicochemical characteristics for recovering valuable metals. The process flow, critical factors, development status, advantages and disadvantages of traditional technologies such as pyrometallurgy, hydrometallurgy and biometallurgy were discussed in depth. Conventional treatment methods typically prioritize separating and reclaiming specific elements with high concentrations. However, these methods face challenges such as excessive chemical usage and limited selectivity, which can hinder the sustainable utilization of smelting dust. With the increasing scarcity of resources and strict environmental requirements, a single treatment process can hardly fulfil the demand, and a physical field-enhanced technology for releasing and separating valuable metals is proposed. Through analysing the effect of electric field, microwave and ultrasound on recovering valuable metals from smelting dust, the enhancement mechanism of physical field on the extraction process was clarified. This paper aimed to provide reference for the resource utilization of smelting dust.

Chemical speciation changes of an all-solid-state lithium-ion battery caused by roasting determined by sequential acid leaching

All-solid-state lithium-ion batteries (ASS-LIBs) are expected to replace current liquid-based LIBs in the near future owing to their high energy density and improved safety. It would be preferable if ASS-LIBs could be recycled by the current recycling processes used for liquid-based LIBs, but this possibility remains to be determined. Here, we subjected an ASS-LIB test cell containing an argyrodite-type solid electrolyte (Li6PS5Cl) and nickel-manganese-cobalt-type active material (Li(Ni0.5Mn0.3Co0.2)O2) to roasting, a treatment process commonly used for recycling of the valuable metals from liquid-based LIBs, and investigated the changes in chemical speciation. Roasting was performed at various temperatures (350-900 °C), for various times (60-360 min), and under various oxygen fugacity (air or O2) conditions. The chemical speciation of each metal element after roasting was determined by sequential elemental leaching tests and X-ray diffraction analysis. Li formed sulfates or phosphates over a wide temperature range. Ni and Co followed very complicated reaction paths owing to coexistence of S, P, and C, and they formed sulfides, phosphates, and complex oxides. The optimum conditions for minimizing formation of insoluble compounds, such as complex oxides, were a roasting temperature of 450-500 °C and a roasting time of 120 min. The results indicated that although ASS-LIBs can be treated by the same roasting processes as those used for current liquid-based LIBs, the optimal roasting conditions have narrow ranges. Thus, careful process control will be needed to achieve high extraction percentages of the valuable metals from ASS-LIBs.

High-efficiency selective leaching of valuable metals from spent lithium-ion batteries: Effects of Na2S2O8 on the leaching of metals

A new method was presented for the high-efficiency selective leaching of Li and the efficient recovery of transition metals (TMs) from the cathode materials of spent lithium-ion batteries (spent LIBs). Selective leaching of Li was achieved by carbothermic reduction roasting and leaching with Na₂S₂O₈. After reduction roasting, high-valence TMs were reduced to low-valence metals or metal oxides, and Li was converted to Li₂CO₃. Then Na₂S₂O₈ solution selectively extracted 94.15% of Li from roasted product with leaching selectivity of more than 99%. At last, TMs were leached with H₂SO₄ without adding reductant with the leaching efficiency of metals all exceeding 99%. Na₂S₂O₈ added during the leaching process destroyed the agglomerated structure of the roasted product to open the way Li entered the solution. Under the oxidative environment of Na₂S₂O₈ solution, TMs would not be extracted. At the same time, it helped to regulate the phase of TMs and improved the extraction of TMs. Furthermore, the phase transformation mechanism of roasting and leaching was discussed through thermodynamic analysis, XRD, XPS, and SEM-EDS. This process not only realized the selectively comprehensive recycling of valuable metals in spent LIBs cathode materials; but also followed the principle of green chemistry.

Recover value metals from spent lithium-ion batteries via a combination of in-situ reduction pretreatment and facile acid leaching

The pretreatment of cathode material before leaching is crucial in the spent lithium-ion battery hydro-metallurgical recycling. Here research demonstrates that in-situ reduction pretreatment could dramatically improve the leaching efficiencies for valuable metals from cathodes. Specifically, calcination under 600 °C without oxygen using alkali treated cathode can induce in-situ reduction and collapse of oxygen framework, which is ascribed to the carbon inherently contained in the sample and promote the following efficient leaching without external reductants. The leaching efficiencies of Li, Mn, Co and Ni can remarkably reach 100%, 98.13%, 97.27% and 97.37% respectively. Characterization methods, such as XRD, XPS and SEM-EDS, were employed and revealed that during in-situ reduction, high valence metals such as Ni³⁺, Co³⁺, Mn⁴⁺ can be effectively reduced to lower valence states, conducive to subsequent leaching reactions. Moreover, leaching processes of Ni, Co and Mn fit well with the film diffusion control model, and the reaction barrier is in accordance with the order of Ni, Co and Mn. In comparison, it is observed that Li was leached with higher efficiency regardless of the various pretreatments. Lastly, an integral recovery process has been proposed and economic assessment demonstrates that in-situ reduction pretreatment increases the benefit with a negligible cost increase.

Sustainable regeneration of high-performance LiCoO2 from completely failed lithium-ion batteries

Utilising the solid-state synthesis method is an easy and effective way to recycle spent lithium-ion batteries. However, verifying its direct repair effects on completely exhausting cathode materials is necessary. In this work, the optimal conditions for direct repair of completely failed cathode materials by solid-state synthesis are explored. The discharge capacity of spent LiCoO₂ cathode material is recovered from 21.7 mAh g^-1 to 138.9 mAh g^-1 under the optimal regeneration conditions of 850 °C and n(Li)/n(Co) ratio of 1:1. The regenerated materials show excellent electrochemical performance, even greater than the commercial LiCoO₂. In addition, based on the whole closed-loop recycling process, the economic and environmental effects of various recycling techniques and raw materials used in the battery production process are assessed, confirming the superior economic and environmental feasibility of direct regeneration method.

Recycling of valuable metals from spent lithium-ion batteries by self-supplied reductant roasting

The massive spent lithium-ion batteries (LIBs) need to be recycled due to their increasing decommission in recent years. This paper aims to propose an effective process that uses self-supplied reductant roasting and acid leaching to recover Lithium, Nickle, Cobalt and Manganese from spent LIBs. In the absence of external carbon resources, the waste membrane from spent LIBs was used as the reductant in the self-supplied reductant roasting. A thermodynamic analysis was conducted to judge the possible reduction reaction between the cathode material and waste membrane. Then, the effects of roasting temperature, roasting time and membrane dosage on the crystal structure and phase transformation of roasting products were investigated and optimized. After the roasting process, the valence state of metals in the cathode material decreased and the structure became loose and porous. Moreover, the layer structure of the cathode material was transformed into groups of Li₂CO₃, Ni, Co, NiO, CoO and MnO. Further, the reduction effect of cathode powders under each roasting condition was verified under the same leaching conditions. After leaching for 30 min, the leaching efficiencies of Li, Ni, Co and Mn were over 99% under the optimum roasting conditions. Finally, economic assessments proved that the proposed process is profitable. The whole process demonstrates an effective and positive way for recycling spent LIBs and making full use of their waste membrane, which promotes resource recovery and environmental protection.

Environmentally sustainable and cost-effective recycling of Mn-rich Li-ion cells waste: Effect of carbon sources on the leaching efficiency of metals using fungal metabolites

Metals recovery from spent lithium coin cells (SCCs) is enjoying great attention due to environmental problems and metal-rich contents such as Mn and Li. Fungi can generate many organic acids, and metals can be dissolved, but sucrose is not an economical medium. The main objective of this study is to find a suitable carbon substrate in place of sucrose for fungal bioleaching. We have developed an environmentally friendly, cost-effective, and green method for recycling and detoxifying Mn and Li from SCCs using the spent culture medium fromPenicillium citrinumcultivation. Sugar cane molasses and sucrose were selected as carbon sources. Based on the extracted fungal metabolites, the effects of pulp density, temperature, and leaching time were assessed on metal dissolution. The most suitable conditions were 30 g/L of pulp density, a temperature of 40 °C, and 4 days of leaching time in spent molasses medium, which led to a high extraction of 87% Mn and 100% Li. Based on EDX-mapping analyses, it was found that the initial concentration of ∑ (Mn + C) in the SCCs powder was almost 100% while reaching nearly 6.4% after bioleaching. After bioleaching, an analysis of residual powder confirmed that metal dissolution from SCCs was effective owing to fungal metabolites. The economic study showed that the bioleaching method is more valuable for the dissolution of metals than the chemical method; In addition to improving bioleaching efficiency, molasses carbon sources can be used for industrial purposes.

Leaching NCM cathode materials of spent lithium-ion batteries with phosphate acid-based deep eutectic solvent

Deep eutectic solvents (DESs) play an important role in efficient recovery of spent lithium-ion batteries (LIBs). In this study, we proposed an efficient and safe method by using a choline chloride-phenylphosphinic acid DES as a lixiviant for the leaching of LiNi_xCo_yMn_zO₂ (NCM) cathode active materials of spent LIBs. The leaching conditions were optimized based on the leaching time, liquid-solid ratio, and leaching temperature. Under optimal experimental conditions, the leaching efficiencies of Li, Co, Ni, and Mn reached 97.7 %, 97.0 %, 96.4 %, and 93.0 %, respectively. The kinetics of the leaching process were well-fitted using the logarithmic law equation. The apparent activation energies for Li, Co, Ni, and Mn have been reported to be 60.3 kJ/mol, 78.9 kJ/mol, 99.3 kJ/mol, and 82.1 kJ/mol, respectively. UV-visible spectroscopy and Fourier transform infrared analysis revealed that the coordination configurations of Ni and Co in the leaching solution were octahedral and tetrahedral, respectively. In addition, the PO bond in phenylphosphinic acid was involved in coordination during leaching. This finding may provide an effective and safe approach for leaching valuable metals from spent LIBs.

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.

Recovery of valuable metals from spent lithium-ion batteries by complexation-assisted ammonia leaching from reductive roasting residue

Recycling valuable metals in spent LIBs is not only in line with the purpose of resource recycling but also an important measure for environmental protection. In this article, a process using biomass reduction roasting followed by a unique complexation-assisted ammonia leaching is proposed. Using waste areca powder (WAP) as a biomass reducing agent, the roasted residue is leached in an aqueous solution for the carbonate. The leaching efficiencies of Ni, Co, and Mn reach over 99% under ammonia leaching conditions of 1.5 M ammonium citrate (AC), 3 M ethylenediamine (EDA). The kinetics of ammonia leaching indicates the activation energies of Ni, Co, and Mn are 51.8 kJ mol^-1, 47.7 kJ mol^-1, and 40.8 kJ mol^-1, respectively, which shows the whole duration is controlled by chemical reactions. Most importantly, this study systematically explores the mechanism of ammonia leaching and provided a useful recommendation for selecting the right ammonium salt.

A clean and efficient process for simultaneous extraction of Li, Co, Ni and Mn from spent Lithium-ion batteries by low-temperature NH4Cl roasting and water leaching

The recycling of valuable metals from spent lithium-ion batteries (LIBs) has great significance for environmental protection and resource conservation. In this paper, a low-temperature clean chlorination roasting-water leaching process was proposed to simultaneously extract Li, Ni, Co and Mn from cathode material (NCM) of spent LIBs. The temperature range of chlorination roasting was determined by thermodynamic analysis to be 250-600 °C. The effect of some factors on the conversion of valuable metals in the process of chlorination roasting and water leaching was systematically studied. The results showed that more than 98 % of Li, Co, Ni and Mn could be extracted under optimized chlorination roasting and water leaching conditions. The chlorination roasting mechanism and phase transformation evolution was determined by means of thermodynamic analysis, TG-DTA, XRD, SEM and EDS. The extraction of valuable metals was realized by the reaction of the metal oxides produced by the decomposition of NCM with NH₄Cl or its evolved HCl to form water-soluble metal chlorides or chlorinated metal-ammonium complexes. The chlorination technique using NH₄Cl provided an effective and clean approach for the simultaneous extraction of Li, Co, Ni and Mn from spent LIBs.

Hydrogen reduction of spent lithium-ion battery cathode material for metal recovery: Mechanism and kinetics

Hydrogen reduction is becoming a promising method for recycling lithium-ion battery cathode materials. However, the reaction mechanism and kinetics during hydrogen reduction are unclear, requiring further investigation. Therefore, non-isothermal and isothermal reduction experiments were conducted to evaluate the temperature dependence of the hydrogen reduction kinetics using simultaneous thermogravimetric and differential thermal analysis equipped with mass spectrometry. XRD and SEM were used to characterize the reduction products to understand the underlying reduction mechanisms. The hydrogen reduction profile could be divided into three main stages: decomposition of cathode materials, reduction of the resultant nickel and cobalt oxides, and reduction of LiMnO2 and residual nickel and cobalt oxides. The hydrogen reduction rate increased with increasing temperature, and 800°C was the optimum temperature for separating the magnetic Ni-Co alloy from the non-magnetic manganese oxide particles. The apparent activation energy for the isothermal tests in the range of 500–700°C was 84.86 kJ/mol, and the rate-controlling step was the inward diffusion of H2(g) within each particle. There was an downward progression of the reduction through the material bed for the isothermal tests in the range of 700–900°C, with an apparent activation energy of 51.82 kJ/mol.

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.

Study on the thermal reduction effect of organic components in spent ternary lithium battery cathode active materials

To improve the adhesion between cathode materials and current collector, and increase the electronic conductivity among electroactive substances, a certain proportion of conductive agents (acetylene black) and agglomerant (PVDF) are usually added in the battery manufacturing process. However, these conductive agents have negative effects on the recovery of cathode materials by pyrolysis or calcination. Recognizing this issue, a method based on the concept of "treating spent with spent" was developed in this paper. Organic matters contained in cathode active materials functioned as the reduction reagents, which can reduce the valence state of transition metals, resulting in the breakdown of the strong chemical bond and the stable layered structure of cathode materials. In this study, the thermal reduction effect of different organic components on cathode active materials was analyzed respectively to evaluate the reduction function of each component. XRD, XPS and ICP-MS were used to compare and analyze changes of phase, element compound state and ion leaching efficiencies of different cathode materials before and after thermal reduction under different amounts of reducing agents. The results show that both PVDF and acetylene black reduced the high-valent metals to low-valent oxides or elemental substances, demonstrating their thermal reduction capabilities. Comparisons of the XRD, XPS analysis and ion leaching results of thermal reduced products suggest that acetylene black has a stronger thermal reduction ability than that of PVDF. The results also show that the reduction of the high nickel cathode material (NCM811) is easier than that of the low nickel cathode material (NCM111).

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

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

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.

Hydrometallurgical recycling of EV lithium-ion batteries: Effects of incineration on the leaching efficiency of metals using sulfuric acid

The growing demand for lithium-ion batteries will result in an increasing flow of spent batteries, which must be recycled to prevent environmental and health problems, while helping to mitigate the raw materials dependence and risks of shortage and promoting a circular economy. Combining pyrometallurgical and hydrometallurgical recycling approaches has been the focus of recent studies, since it can bring many advantages. In this work, the effects of incineration on the leaching efficiency of metals from EV LIBs were evaluated. The thermal process was applied as a pre-treatment for the electrode material, aiming for carbothermic reduction of the valuable metals by the graphite contained in the waste. Leaching efficiencies above 70% were obtained for Li, Mn, Ni and Co after 60 min of leaching even when using 0.5 M sulfuric acid, which can be linked to the formation of more easily leachable compounds during the incineration process. When the incineration temperature was increased (600-700 °C), the intensity of graphite signals decreased and other oxides were identified, possibly due to the increase in oxidative conditions. Higher leaching efficiencies of Mn, Ni, Co, and Li were reached at lower temperatures of incineration (400-500 °C) and at higher leaching times, which could be related to the partial carbothermic reduction of the metals.

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

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

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.