Recovery of critical metals from EV batteries via thermal treatment and leaching with sulphuric acid at ambient temperature

Fe3+ and Al3+ removal by phosphate and hydroxide precipitation from synthetic NMC Li-ion battery leach solution

The removal of trivalent iron and aluminum was studied from synthetic Li-ion battery leach solution by phosphate and hydroxide precipitation (pH 2.5-4.25, t = 3 h, T = 60 °C). Phosphate precipitation exhibited both crystal nucleation initiation (pH 2 vs. pH 3) as well as complete (~ 99%) Fe and Al removal at lower pH compared to hydroxide precipitation (pH 3 vs. 3.5). The precipitation time of phosphate was shorter (40 min) than that of hydroxide precipitation (80 min). At pH 4 the loss of valuable metals (Li, Ni, Co) in the precipitate was negligible in the phosphate cake, whereas in the hydroxide process the co-precipitation was 4-5% for Li, Ni and Co. The filtration rate of phosphate precipitate was shown to be significantly faster. The presence of fluoride did not have any notable effect on phosphate precipitation, whereas in hydroxide precipitation, it potentially had a negative effect on aluminum extraction.

Lithium-ion battery recycling: a source of per- and polyfluoroalkyl substances (PFAS) to the environment?

Recycling of lithium-ion batteries (LIBs) is a rapidly growing industry, which is vital to address the increasing demand for metals, and to achieve a sustainable circular economy. Relatively little information is known about the environmental risks posed by LIB recycling, in particular with regards to the emission of persistent (in)organic fluorinated chemicals. Here we present an overview on the use of fluorinated substances - in particular per- and polyfluoroalkyl substances (PFAS) - in state-of-the-art LIBs, along with recycling conditions which may lead to their formation and/or release to the environment. Both organic and inorganic fluorinated substances are widely reported in LIB components, including the electrodes and binder, electrolyte (and additives), and separator. Among the most common substances are LiPF6 (an electrolyte salt), and the polymeric PFAS polyvinylidene fluoride (used as an electrode binder and a separator). Currently the most common LIB recycling process involves pyrometallurgy, which operates at high temperatures (up to 1600 °C), sufficient for PFAS mineralization. However, hydrometallurgy, an increasingly popular alternative recycling approach, operates under milder temperatures (<600 °C), which could favor incomplete degradation and/or formation and release of persistent fluorinated substances. This is supported by the wide range of fluorinated substances detected in bench-scale LIB recycling experiments. Overall, this review highlights the need to further investigate emissions of fluorinated substances during LIB recycling and suggests that substitution of PFAS-based materials (i.e. during manufacturing), or alternatively post-treatments and/or changes in process conditions may be required to avoid formation and emission of persistent fluorinated substances.

The economic and environmental impacts of shared collection service systems for retired electric vehicle batteries

One of the impending consequences of the rapid penetration of electric vehicles (EVs) is that a substantial amount of expired EV batteries will present an increasing waste collection and management problem, particularly in the urban context. Motivated by a lack of research on this issue, this paper comprehensively evaluates the relative benefits of shared versus non-shared collection systems, where the service outlets are not exclusive to specified automakers. Using a mixed-integer optimization model, the analysis features spatiotemporal and multiple stakeholder complexities. Based on the historical monthly EV sales data from 2016 to 2021, a representative case study of Beijing, China is conducted, including 16 district centers, 32 major automobile manufacturers, 153 collection service outlets and 4 disposal centers. The results show that a shared collection service system leads to higher profitability, higher collection rates, increased environmental benefits and improved facility utilization. Consequently, this research contributes to supply chain liberalization to foster the efficient waste management of EV batteries. With a further model extension, it can also provide decision support for the policy-making of more countries.