Anode carbonaceous material recovered from spent lithium-ion batteries in electric vehicles for environmental application

A comprehensive approach for the recycling of anode materials from spent lithium-ion batteries: Separation, lithium recovery, and graphite reutilization as environmental catalyst

The effective recovery of valuables from anodes coming from spent lithium-ion batteries (LIBs) is of great importance to ensure resource supply and reduce the environmental burden for recycling. In this work, a simple and low energy consumption roasting method was proposed by employing low-temperature eutectic NaOH-KOH as reaction medium, in order to simultaneously separate graphite from Cu foils, extract lithium from it and set it up for reuse as environmental catalyst through one-step water washing process. Our results show that polyvinylidene difluoride (PVDF) was effectively deactivated due to dehydrofluorination/carbonization at a relatively low temperature and short time (150 °C, 20 min) when a mass ratio of 1:1 for eutectic NaOH-KOH to spent LIBs anodes was used, yielding 97.3 % of graphite detached. Moreover, a remarkable lithium extraction efficiency of 93.2 % was simultaneously obtained. Afterwards, the reusability of the recycled graphite was tested by employing it as a catalyst for the treatment of a contaminant organic dye (Rhodamine B) in the presence of NaClO. Our results show that a superior NaClO activation was obtained with the addition of recycled graphite, being this fact closely associated to the abundant active sites formed during the long-term charging/discharging cycles in the original battery. The alkaline-mediated roasting process presented in this work presents an energy-saving scheme to efficiently recover useful components from spent anodes, whereas the reusability example highlighted a useful option for repurposing the severely damaged graphite as an environmental catalyst rather than disposing it in landfills, turning waste into a valuable material.

Opportunity and challenges in recovering and functionalizing anode graphite from spent lithium-ion batteries: A review

Recent concerns have emerged regarding the improper disposal of spent lithium-ion batteries (LIBs), which has garnered widespread societal attention. Graphite materials accounted for 12-21 wt % of LIBs' mass, typically contain heavy metals, binders, and residual electrolytes. Regenerating spent graphite not only alleviated the shortage of plumbago, but also contributed to the supports environmental protection as well as national carbon peak and neutrality ("dual carbon" goals). Despite significant advancements in recycling spent LIBs had been made, a comprehensive overview of the processes for pretreatment, regeneration, and functionalization of spent graphite from retired LIBs, along with the associated technical standards and industry regulations enabling their smooth implementation still needed to be mentioned. Hence, we conducted the following research work. Firstly, the pre-treatment process of spent graphite, including discharging, crushing, and screening was summed up. Next,. Subsequently, graphite recovery methods, such as acid leaching, pyrometallurgy, and combined methods were summarized. Moreover, the modification and doping approach was used to enhance the electrochemical properties of graphite. Afterwards, we reviewed the functionalization of anode graphite from an economically and environmentally friendly view. Meanwhile, the technical standards and industry regulations of spent LIBs in domestic and oversea industries were described. Finally, we provided an overview of the technical challenges and development bottlenecks in graphite recycling, along with future prospects Overall, this study outlined the opportunities and challenges in recovering and functionalizing of anode materials via a efficient and sustainable processes.

Recycling Graphite from Spent Lithium Batteries for Efficient Solar-Driven Interfacial Evaporation to Obtain Clean Water

Solar-driven interfacial evaporation technology is regarded as an attracting sustainable strategy for obtaining portable water from seawater and wastewater, and the recycle of waste materials to fabricate efficient photothermal materials as evaporator to efficiently utilize solar energy is very critical, but still difficult. To this purpose, graphite recovered from spent lithium-ion batteries (SLIBs) was realized using a simple acid leaching method, and a reconstructed graphite-based porous hydrogel (RG-PH) was subsequently fabricated by crosslinking foaming method. The incorporation of reconstructed graphite (RG) improves the mechanical characteristics of hydrogels and the light absorption performance significantly. The evaporation rate of optimized RG-PH can constantly reach 3.4278 kg m-2  h-1 for desalination under a one solar irradiation, and it also showed the excellent salt resistance in various salty water. Moreover, RG-PH has a strong elimination of a variety of organic contaminants in wastewater, including the typical volatile organic compound of phenol. This research shows the potential application of flexible and durable solar evaporators made from waste materials in purifying seawater and wastewater, not only contributing to carbon neutrality by recycling graphite from SLIBs, but also ensuring the cost-effectiveness harvest of solar energy for constantly obtaining clean water.

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.

Degradation of phenol by perborate in the presence of iron-bearing and carbonaceous materials

We investigated the oxidation of phenol by perborate-a newly proposed oxidant-in the presence of iron-bearing and carbonaceous materials through batch experiments. We hypothesized that the oxidation of phenol by perborate was enhanced due to the formation of reactive oxygen species (ROS) in the presence of iron-bearing or carbonaceous materials. Zero-valent iron and ferrous iron (Fe2+) promoted the oxidation of phenol by perborate. Biochar, granular activated carbon, an anode carbonaceous material recovered from a spent Li-ion battery, and graphite also accelerated the oxidation of phenol by perborate. Quenching experiments with radical scavengers and electron paramagnetic resonance (EPR) analysis revealed that hydroxyl (˙OH) and superoxide (O2˙-) radicals were generated and enhanced the degradation of phenol in the perborate systems. Singlet oxygen (1O2) was involved in the iron-bearing material-perborate systems. Moreover, we found that Persil®, a commercial perborate detergent, enhances the oxidation of phenol in the presence of iron-bearing and carbonaceous materials. Our results suggest that perborate can be used for advanced oxidation processes to remediate recalcitrant organic contaminants in natural environments and engineered systems.

The Foreseeable Future of Spent Lithium-Ion Batteries: Advanced Upcycling for Toxic Electrolyte, Cathode, and Anode from Environmental and Technological Perspectives

With the rise of the new energy vehicle industry represented by Tesla and BYD, the need for lithium-ion batteries (LIBs) grows rapidly. However, owing to the limited service life of LIBs, the large-scale retirement tide of LIBs has come. The recycling of spent LIBs has become an inevitable trend of resource recovery, environmental protection, and social demand. The low added value recovery of previous LIBs mostly used traditional metal extraction, which caused environmental damage and had high cost. Beyond metal extraction, the upcycling of spent LIBs came into being. In this work, we have outlined and particularly focus on sustainable upcycling technologies of toxic electrolyte, cathode, and anode from spent LIBs. For electrolyte, whether electrolyte extraction or decomposition, restoring the original electrolyte components or decomposing them into low-carbon energy conversion is the goal of electrolyte upcycling. Direct regeneration and preparation of advanced materials are the best strategies for cathodic upcycling with the advantages of cost and energy consumption, but challenges remain in industrial practice. The regeneration of advanced graphite-based materials and battery-grade graphite shows us the prospect of regeneration of anode. Furthermore, the challenges and future development of spent LIBs upcycling are summarized and discussed from technological and environmental perspectives.

Recycle graphite from spent lithium-ion batteries for H2O2 electrosynthesis

On-site H2O2 synthesis via the two-electron route oxygen reduction reaction for environmental remediation is attractive. This work offers a novel strategy for both spent graphite recovery and H2O2 electrosynthesis catalyst preparation. The graphite is directly recycled from spent lithium-ion batteries to an H2O2 electrosynthesis catalyst. From the view of sustainable development and environmental protection, the H2O2 electrosynthesis catalyst prepared using spent graphite is eco-friendly and cost-efficient. The surface functional groups of the recycled graphite are finely tuned by the HNO3 medium to induce -COOH and C-O-C groups. The activated graphite exhibits high H2O2 activity and selectivity, compared to the raw spent graphite. The activated graphite can achieve an H2O2 Faradic efficiency of about 80%. The activated graphite has a good prospect for T-acid wastewater treatment as the H2O2 generation catalyst. Almost 92% of chemical oxygen demand can be removed.

Advances and challenges in anode graphite recycling from spent lithium-ion batteries

Spent lithium-ion batteries (LIBs) have been one of the fast-growing and largest quantities of solid waste in the world. Spent graphite anode, accounting for 12-21 wt% of batteries, contains metals, binders, toxic, and flammable electrolytes. The efficient recovery of spent graphite is urgently needed for environmental protection and resource sustainability. Recently, more and more studies have been focused on spent graphite recycling, while the advance and challenges are rarely summarized. Hence, this study made a comprehensive review of graphite recycling including separation, regeneration, and synthesis of functional materials. Firstly, the pretreatment of graphite separation was overviewed. Then, the spent graphite regeneration methods such as leaching, pyrometallurgy, their integration processes, etc. were systematically introduced. Furthermore, the modification strategies to enhance the electrochemical performance were discussed. Subsequently, we reviewed in detail the synthesis of functional materials using spent graphite for energy and environmental applications including graphene, adsorbents, catalysts, capacitors, and graphite/polymer composites. Meanwhile, we briefly compared the economic and environmental benefits of graphite regeneration and other functional materials production. Finally, the technical bottlenecks and challenges for spent graphite recycling were summarized and some future research directions were proposed. This review contributes to spent LIBs recycling more efficiently and profitably in the future.

A critical review of the circular economy for lithium-ion batteries and photovoltaic modules - status, challenges, and opportunities

To meet net-zero emissions and cost targets for power production, recent analysis indicates that photovoltaic (PV) capacity in the United States could exceed 1 TW by 2050 alongside comparable levels of energy storage capacity, mostly from batteries. For comparison, the total U.S. utility-scale power capacity from all energy sources in 2020 was 1.2 TW, of which solar satisfied approximately 3%. With such massive scales of deployment, questions have arisen regarding issues of material supply for manufacturing, end-of-life management of technologies, environmental impacts across the life cycle, and economic costs to both individual consumers and society at large. A set of solutions to address these issues center on the development of a circular economy - shifting from a take-make-waste linear economic model to one that retains the value of materials and products as long as possible, recovering materials at end of life to recirculate back into the economy. With limited global experience, scholars and practitioners have begun to investigate circular economy pathways, focusing on applying novel technologies and analytical methods to fast-growing sectors like renewable energy. This critical review aims to synthesize the growing literature to identify key insights, gaps, and opportunities for research and implementation of a circular economy for two of the leading technologies that enable the transition to a renewable energy economy: solar PV and lithium-ion batteries (LIBs). We apply state-of-the-science systematic literature review procedures to critically analyze over 3,000 publications on the circular economy of solar PV and LIBs, categorizing those that pass a series of objective screens in ways that can illuminate the current state of the art, highlight existing impediments to a circular economy, and recommend future technological and analytical research. We conclude that while neither PV nor LIB industries have reached a circular economy, they are both on a path towards increased circularity. Based on our assessment of the state of current literature and scientific understanding, we recommend research move beyond its prior emphasis on recycling technology development to more comprehensively investigate other CE strategies, more holistically consider economic, environmental and policy aspects of CE strategies, increase leveraging of digital information systems that can support acceleration towards a CE, and to continue to study CE-related aspects of LIB and PV markets.

Separation and Comprehensive Recovery of Cobalt, Nickel, and Lithium from Spent Power Lithium-Ion Batteries

The popularization of electric vehicles drives the extensive use of power lithium-ion batteries (LIBs) and their abandonment after retirement. Spent power LIBs have a high economic value because they contain valuable metals which need to be recovered. In this study, the separation and comprehensive recovery of valuable metallic elements, including Co, Ni, and Li, from spent power LIBs were realized by a hydrometallurgical process of “calcination–leaching–synergistic extraction–synthesis”. The results showed that, under the optimal conditions, the extraction efficiencies of impurities, such as Al and Cu, by P204 were 91% and 90%, respectively. A P507–N235 synergistic system was proposed to extract Co over Ni and Li with the maximum synergistic coefficient of 12.6. The extraction efficiency of Co, Ni, and Li was 99.5%, 3.9%, and 9.7%, respectively, and the separation coefficients of β(Co/Ni) and β(Co/Li) were 200.6 and 300.3, respectively. Cobalt oxalate, nickel oxalate, and lithium carbonate were finally obtained. Comprehensive recovery of valuable metals was realized, and the total recovery efficiency of Li, Ni, and Co was 84.1%, 93.1%, and 96.5%, respectively. This study provides positive significance for the improvement of cobalt extraction technology and comprehensive recycling efficiency of spent power LIBs.

Hydrometallurgical enhanced liberation and recovery of anode material from spent lithium-ion batteries

The efficient recycling of spent anode material (SAM) from spent lithium-ion batteries (LIBs) is generally critical in terms of electronic waste recyclingas well as increasing resource shortage and environmental problems. This research reported a novel and green method to recycle lithium, copper foil, and graphite from SAM by water leaching treatment. The results indicated that 100% of graphite was exfoliated from the anode material and 92.82% leaching efficiency of lithium was obtained under the optimal conditions of 80 °C, 60 g/L, 300 rpm, and 60 min, respectively. This finding revealed that the SAM got a full liberation characteristic due to the removal of binder, which produced an ideal leaching lithium efficiency rivaling the acids' performance. The mechanism of the liberation of SAM and lithium leaching is presented based on the analysis of results. The graphite was purified and recovered after water leaching treatment. Besides, lithium was recovered in the form of lithium carbonate (Li₂CO₃)_, and the copper foil was recovered in a sheet. This study endeavors to develop an economical and environmentally feasible plan to recycle graphite, copper, and lithium from SAM.