Selective recovery of lithium and iron phosphate/carbon from spent lithium iron phosphate cathode material by anionic membrane slurry electrolysis

Emerging Processes for Sustainable Li-Ion Battery Cathode Recycling

The colossal growth in the use of Li-ion batteries (LiBs) has raised serious concerns over the supply chain of strategic minerals, e.g., Co, Ni, and Li, that make up the cathode active materials (CAM). Recycling spent LiBs is an important step toward sustainability that can establish a circular economy by effectively tackling large amounts of e-waste while ensuring an unhindered supply of critical minerals. Among the various methods of LiB recycling available, pyro- and hydrometallurgy have been utilized in the industry owing to their ease of operation and high efficiency, although they are associated with significant environmental concerns. Direct recycling, a more recent concept that aims to relithiate spent LiBs without disrupting the lattice structure of the CAMs, has been realized only in the laboratory scale so far and further optimization is required before it can be extended to the bulk scale. Additionally, significant progress has been made in the areas of hydrometallurgy in terms of using ecofriendly green lixiviants and alternate sources of energy, e.g., microwave and electrochemical, that makes the recycling processes more efficient and sustainable. In this review, the latest developments in LiB recycling are discussed that have focused on environmental and economic viability, as well as process intensification. These include deep eutectic solvent based recycling, electrochemical and microwave-assisted recycling, and various types of direct recycling.

Physicochemical reactions in e-waste recycling

Electronic waste (e-waste) recycling is becoming a global concern owing to its immense quantity, hazardous character and the potential loss of valuable metals. The many processes involved in e-waste recycling stem from a mixture of physicochemical reactions, and understanding the principles of these reactions can lead to more efficient recycling methods. In this Review, we discuss the principles behind photochemistry, thermochemistry, mechanochemistry, electrochemistry and sonochemistry for metal recovery, polymer decomposition and pollutant elimination from e-waste. We also discuss how these processes induce or improve reaction rates, selectivity and controllability of e-waste recycling based on thermodynamics and kinetics, free radicals, chemical bond energy, electrical potential regulation and more. Lastly, key factors, limitations and suggestions for improvements of these physicochemical reactions for e-waste recycling are highlighted, wherein we also indicate possible research directions for the future.

Addressing preliminary challenges in upscaling the recovery of lithium from spent lithium ion batteries by the electrochemical method: a review

The paramount importance of lithium (Li) nowadays and the mounting volume of untreated spent LIB have imposed pressure on innovators to tackle the near-term issue of Li resource depletion through recycling. The trajectory of research dedicated to recycling has skyrocketed in this decade, reflecting the global commitment to addressing the issues surrounding Li resources. Although metallurgical methods, such as pyro- and hydrometallurgy, are presently prevalent in Li recycling, they exhibit unsustainable operational characteristics including elevated temperatures, the utilization of substantial quantities of expensive chemicals, and the generation of emissions containing toxic gases such as Cl2, SO2, and NOx. Therefore, the alternative electrochemical method has gained growing attention, as it involves a more straightforward operation leveraging ion-selective features and employing water as the main reagent, which is seen as more environmentally benign. Despite this, intensive efforts are still required to advance the electrochemical method toward commercialisation. This review highlights the key points in the electrochemical method that demand attention, including the feasibility of a large-scale setup, consideration of the substantial volume of electrolyte consumption, the design of membranes with the desired features, a suitable layout of the membrane, and the absence of techno-economic assessments for the electrochemical method. The perspectives presented herein provide a crucial understanding of the challenges of advancing the technological readiness level of the electrochemical method.

Comprehensive Technology for Recycling and Regenerating Materials from Spent Lithium Iron Phosphate Battery

The lithium iron phosphate (LFP) battery has been widely used in electric vehicles and energy storage for its good cyclicity, high level of safety, and low cost. The massive application of LFP battery generates a large number of spent batteries. Recycling and regenerating materials from spent LFP batteries has been of great concern because it can significantly recover valuable metals and protect the environment. This paper aims to critically assess the latest technical information available on the echelon utilization and recycling of spent LFP batteries. First, it focuses on the progress of disassembly, evaluation and detection, regrouping, and application in echelon utilization. Then, the recycling technologies, including pretreatment, direct repair, and material regeneration, of spent LFPs are summarized. Finally, the paper proposes some challenges in the echelon utilization and recycling of spent LFP batteries, and concludes with recommendations for an intelligent, refined, and clean LFP battery circulation system that are required to ensure the sustainable development of spent LFP battery recycling.

Clean and efficient synthesis of LiFePO4 cathode material using titanium white waste and calcium dihydrogen phosphate

Large amounts of titanium white waste are generated in the production of titanium dioxide using sulphate method, which in turn can be used to prepare LiFePO4 cathode material, thereby reducing environmental risks and achieving resource recovery. However, a key challenge lies in the elimination of impurities. In this work, a cost-efficient and straightforward approach based on phase transformation during hydrothermal treatment was proposed to utilize titanium white waste with calcium dihydrogen phosphate for the preparation of LiFePO4 cathode material. The content of Fe in the leachate was enriched to 81.5 g/L after purification, while 99.9 % of Ti and 98.36 % of Al and were successfully removed. In the subsequent process for Fe/P mother liquor preparation, the losses of Fe and P were only 5.82 % and 2.81 %, respectively. The Fe and P contents of the synthesized FePO4 product were 29.47 % and 17.08 %, respectively, and the Fe/P molar ratio was 0.986. Crystal phase of the product matched well with standard iron phosphate, and the lamellar microstructure of FePO4 was uniform with the particle size ranging from 3 to 5 μm. Moreover, the contents of impurities in the product were far below the standard. The initial discharge of LiFePO4 synthesized by the iron phosphate was 160.6 mAh.g-1 at 0.1C and maintained good reversible capacity after 100 cycles. This work may provide new strategy for preparing LiFePO4 cathode material from industrial solid waste.

Electrochemical selective lithium extraction and regeneration of spent lithium iron phosphate

In this paper, a green, efficient and low-cost process for the selective recovery of lithium from spent LiFePO4 by anodic electrolysis is proposed. The leaching rates of Li, Fe and P under different conditions were explored and the optimal conditions are obtained. In the optimal conditions, Li, Fe and P leaching rates were 96.31%, 0.06% and 0.62% respectively. The Li/Fe selectivity was over 99.9%. The product obtained is isostructural FePO4 and retains the original particle morphology. The FePO4 obtained can be synthesised into LiFePO4/C by direct regeneration process or impurity removal regeneration process. The material synthesized by the latter process has a better electrochemical performance, with a discharge specific capacity of 144.5 mAh/g at 1.0C and a capacity retention of 92.0% over 500cycles. The superior performance can be attributed to an impurity removal process that reduced agglomeration and improved particle morphology.

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.

Recycling technologies, policies, prospects, and challenges for spent batteries

The recycling of spent batteries is an important concern in resource conservation and environmental protection, while it is facing challenges such as insufficient recycling channels, high costs, and technical difficulties. To address these issues, a review of the recycling of spent batteries, emphasizing the importance and potential value of recycling is conducted. Besides, the recycling policies and strategies implemented in representative countries are summarized, providing legal and policy support for the recycling industry. Moreover, a comprehensive classification and comparison of recycling technologies identify the characteristics and current status of different approaches. The integrated recycling technology provides a better recycling performance with zero-pollution recycling of spent battery. Biorecycling technology is expected to gain a broad development prospect in the future owing to the superiority of energy-saving and environmental protection, high recycling efficiency, via microbial degradation, enzymatic degradation, etc. Consequently, as for the existing recycling challenges of waste batteries, developing new recycling technology and perfecting its recycling system is an indispensable guarantee for the sustainable development of waste battery. Meanwhile, theoretical support is offered for the recycling of spent batteries.

Direct selective leaching of lithium from industrial-grade black mass of waste lithium-ion batteries containing LiFePO4 cathodes

Demand for lithium-ion batteries (LIBs) is projected to maintain unprecedented acceleration for decades, towards satisfying international climate and source objectives. LIB wastes pose a threat to the environment, but also may be considered a strategic, high-grade resource. Yet, recycling the black mass of waste LIBs, which contains plastic, C, Li, Fe, Ni, Co, Mn, Cu, and Al, is very complex. Herein, the direct selective leaching of Li from the industrial-grade black mass powder of waste LIBs is proposed for the first time. Results demonstrated that the leaching efficiency of Li is shown to exceed 97%, while other metals remain below 1%. The mechanism of selective leaching was also investigated in this study. Under the experimental conditions, Fe is not leached out and remains in the form of solid FePO4. As for other impurity metal elements, they are removed from the solution due to the alkaline environment of the post-leaching solution and the adsorption effect of the anodic carbon. Furthermore, the alkaline post-leaching solution can avoid the neutralizing stage before the precipitation of lithium salts. This highly efficient and Li-selective leaching strategy offers a broadly applicable approach to reclaiming critical energy minerals from the black mass of wasted LIBs.

Preparation and Lithium-Ion Separation Property of ZIF-8 Membrane with Excellent Flexibility

Metal-organic framework (MOF) membranes exhibit immense potential for separation applications due to their regular pore channels and scalable pore sizes. However, structuring a flexible and high-quality MOF membrane remains a challenge due to its brittleness, which severely restricts its practical application. This paper presents a simple and effective method in which continuous, uniform, defect-free ZIF-8 film layers of tunable thickness are constructed on the surface of inert microporous polypropylene membranes (MPPM). To provide heterogeneous nucleation sites for ZIF-8 growth, an extensive amount of hydroxyl and amine groups were introduced on the MPPM surface using the dopamine-assisted co-deposition technique. Subsequently, ZIF-8 crystals were grown in-situ on the MPPM surface using the solvothermal method. The resultant ZIF-8/MPPM exhibited a lithium-ion permeation flux of 0.151 mol m^-2 h^-1 and a high selectivity of Li⁺/Na⁺ = 1.93, Li⁺/Mg²⁺ = 11.50. Notably, ZIF-8/MPPM has good flexibility, and the lithium-ion permeation flux and selectivity remain unchanged at a bending curvature of 348 m^-1. These excellent mechanical characteristics are crucial for the practical applications of MOF membranes.

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.

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.

Research on Bayer Red Mud Slurry Electrolysis

The Bayer red mud is the solid waste generated during the production of alumina by the Bayer process. At present, the stock of red mud in China exceeds 1.1 billion tons, covering an area of more than 120,000 mu, and the annual production volume is increasing by 100 million tons. The comprehensive utilization of red mud is still a difficult problem. Therefore, it is of great significance to actively explore new methods for removing sodium from red mud. In this study, the traditional red mud desalination process and the slurry electrolysis process are combined, and the influence of three different leaching agents on the leaching and sodium removal of red mud slurry in the presence of an electric field is explored. In the slurry electrolysis experiment, it was found that the sodium removal rate obtained by different leaching agents was CaO > CaCl₂ > HCl. The red mud leached with pure dilute hydrochloric acid has the highest Na removal rate, which is 93.11%. In view of this situation, a pre-slurry-electrolysis cycle process with HCl as leaching agent was proposed. The core of slurry electrolysis is electrolyzing NaCl solution, and HCl only participates in the process as circulating medium. The design of this process reduces cost and increases efficiency.

Aluminum separation by sulfuric acid leaching-solvent extraction from Al-bearing LiFePO4/C powder for recycling of Fe/P

Recovery of battery-grade FePO₄ from Al-bearing spent LiFePO₄ batteries (LFPs) is important for both prevention of environmental pollution and recycling of resources for LFPs industries. The premise for FePO₄ recovery from spent LFPs is the separation of Al, because Al readily co-precipitates with FePO₄ and lowers the electrochemical performance of the regenerated LiFePO₄. In this work, an efficient approach involving sulfuric acid leaching followed by solvent extraction was developed to separate Al from spent LiFePO₄/C powder. Di-(2-ethylhexyl) phosphoric acid (D2EHPA) in sulfonated kerosene was used as the extractant. The results showed that 96.4% of aluminum was extracted while the loss of iron was only 1.1% under the optimal conditions. The mass fraction of Al in the iron phosphate obtained from the extraction raffinate was only 0.007%, meeting the standard for preparing battery-grade FePO₄. The extracted Al can be easily stripped by diluted H₂SO₄ solution and the extractants can be reused. Additionally, slope analysis method, FTIR spectroscopy, and ESI-MS analysis revealed that the extraction of Al in D2EHPA can be ascribed to the ion exchange between hydrogen ion of -PO(OH) and Al³⁺. This work may provide an economically feasible method for the recycling of valuable components from spent Al-bearing LiFePO₄/C powder.

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.

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.