Repurposing of spent lithium-ion battery separator as a green reductant for efficiently refining the cathode metals

Pre-separation combined with reduction roasting for high-quality recovery of graphite and lithium from spent lithium ion batteries

The recycling of spent lithium ion batteries is of great significance because it contains large amounts of valuable metals. But current recovery methods exhibit limited efficiency in selectively extracting lithium from spent electrode materials and spent graphite becomes metallurgical residues. In this study, we propose a novel recycling flowchart that combines flotation with multi-stage water-leaching to enhance the recovery of graphite and lithium from black mass derived from spent lithium ion batteries. Removal of organics can be conducted by pyrolysis, at the same time, the spent ternary cathode material was decomposed into CoO, NiO, and MnO at a temperature of 600 °C for 60 min using pyrolysis product-derived reductant. The sub-microlevel migration behavior of lithium ions in electrode materials was also examined. The electrode material aggregates were broken up by water crushing, and 38.67 % lithium dissolves into water for recycling. Bubble flotation was used to recycle the excess graphite from the black mass while the residual graphite was used as reductant for the carbothermal reduction. Using the developed scheme, we were able to recover 95.51 % of lithium after carbothermal reduction with 12.31 % carbon residue. Based on basic research, a novel recycling flowchart of spent lithium-ion batteries has been proposed.

One-stone, two birds: One step regeneration of discarded copper foil in zinc battery for dendrite-free lithium deposition current collector

The ever-growing requirement for electrochemical energy storage has exacerbated the production of spent batteries, and the recycling of valuable battery components has recently received a remarkable attention. Among all battery components, copper foil is widely utilized as a current collector for stable zinc platting and stripping in zinc metal batteries (ZMBs) due to the perfect lattice matching of between metal copper and zinc, which is accompanied by the formation of multiple copper-zinc alloy components during the cycling process. Herein, a novel "two birds with one-stone" strategy through a one simple heat treatment step to revive the discarded copper foil in zinc metal battery is reported to further obtain a lithiophilic current collector (CuxZny-Cu) with multiple copper-zinc alloy components on the surface of the discarded copper foil. Such revived CuxZny-Cu current collector greatly reduces the lithium nucleation overpotential and realizes uniform lithium deposition and further inhibits lithium dendrites growth. The formed multiple CuxZny alloy phases on the surface of discarded copper foil exhibit a low Li nucleation overpotential of only 15 mV at 0.5 mA cm-2 for the first cycle. Moreover, such a CuxZny-Cu current collector could achieve stable cycle for 220 cycles at 0.5 mA cm-2 and 110 cycles at 1 mA cm-2 with a Li plating capacity of 1 mAh cm-2. Theoretical calculations indicate that, compared with pure Cu foil, the formed multiple alloy components of CuZn5, CuZn8, Cu0.61Zn0.39 and CuZn have low adsorption energy of -2.17, -2.55, -2.16 and -2.35 eV with lithium atoms, respectively, which result in reduced lithium nucleation overpotential. The full cell composed of CuxZny alloy current collector with deposition of 5 mAh cm-2 metal Li anode coupled with LiFePO4 (LFP) cathode exhibits a reversible capacity of 125.6 mAh/g after 110 cycles at a current of 0.5 C with capacity retention of 85.1 %. This work proposed a promising strategy to regenerate the discarded copper foil in rechargeable batteries.

Recycling of spent lithium-ion batteries for a sustainable future: recent advancements

Lithium-ion batteries (LIBs) are widely used as power storage systems in electronic devices and electric vehicles (EVs). Recycling of spent LIBs is of utmost importance from various perspectives including recovery of valuable metals (mostly Co and Li) and mitigation of environmental pollution. Recycling methods such as direct recycling, pyrometallurgy, hydrometallurgy, bio-hydrometallurgy (bioleaching) and electrometallurgy are generally used to resynthesise LIBs. These methods have their own benefits and drawbacks. This manuscript provides a critical review of recent advances in the recycling of spent LIBs, including the development of recycling processes, identification of the products obtained from recycling, and the effects of recycling methods on environmental burdens. Insights into chemical reactions, thermodynamics, kinetics, and the influence of operating parameters of each recycling technology are provided. The sustainability of recycling technologies (e.g., life cycle assessment and life cycle cost analysis) is critically evaluated. Finally, the existing challenges and future prospects are presented for further development of sustainable, highly efficient, and environmentally benign recycling of spent LIBs to contribute to the circular economy.

Green Synergy Conversion of Waste Graphite in Spent Lithium-Ion Batteries to GO and High-Performance EG Anode Material

The increasing demand for graphite and the higher lithium content than environment abundance make the recycling of anode in spent lithium-ion batteries (LIBs) also become an inevitable trend. This work proposes a simple pathway to convert the retired graphite to high-performance expanded graphite (EG) under mild conditions. After the oxidation and intercalation by FeCl3 for the retired graphite, H2O2 molecules are more likely to penetrate into the extended layers. And the gas phase diffusion caused by the produced O2 from the redox reaction between FeCl3 and H2O2 further promotes lattice expansion of interlayers (0.535 nm), which is beneficial to the stripping of graphene oxide (GO) with fewer layers. The EG exhibits excellent electrochemical performances in both LIBs and sodium-ion batteries (SIBs). It delivers 331.5 mAh g-1 at 3C (1C = 372 mA g-1) in LIBs, while it achieves 176.8 mAh g-1 at 3C (1C = 120 mA g-1) in SIBs. Then the capacity retains 753.6 (LIBs) and 201.6 (SIBs) mAh g-1 after a long-term cycling of 500 times at 1C, respectively. The full cells with the EG electrodes after prelithium/presodiation also show excellent cycle stability. Thus, this work offers another referable strategy for the recycling of waste graphite in spent LIBs.

Leaching Li from mixed cathode materials of spent lithium-ion batteries via carbon thermal reduction

The use of a carbon thermal reduction roasting method to recover lithium resources from spent lithium-ion batteries (S-LIBs) provides an important opportunity for recycling S-LIBs. The preferential extraction of Li via reduction roasting has been widely studied; however, the extraction of Li from mixed cathode materials has been rarely reported. Herein, we propose a method based on carbon thermal reduction to preferentially extract Li from mixed cathode materials. It was confirmed that there are differences in carbon thermal reduction products at 700 °C-850 °C by the thermodynamic analysis of the carbon thermal reduction process. At the same time, the effects of factors such as roasting temperature, roasting time, and material ratio on Li leaching efficiency were investigated. The Li recovery rate reached 98.86% under the optimal conditions of holding at 750 °C for 4 h with a molar ratio of mixed cathode materials to graphite of 1 : 0.25. Recovered Li2CO3 can be directly used as a lithium source for the regeneration of cathode materials. This study will provide new opportunities for the efficient recycling of spent lithium-ion batteries (S-LIB) mixtures.

Recycling Valuable Metals from Spent Lithium-Ion Batteries Using Carbothermal Shock Method

Pyrometallurgy technique is usually applied as a pretreatment to enhance the leaching efficiencies in the hydrometallurgy process for recovering valuable metals from spent lithium-ion batteries. However, traditional pyrometallurgy processes are energy and time consuming. Here, we report a carbothermal shock (CTS) method for reducing LiNi_0.3 Co_0.2 Mn_0.5 O₂ (NCM325) cathode materials with uniform temperature distribution, high heating and cooling rates, high temperatures, and ultrafast reaction times. Li can be selectively leached through water leaching after CTS process with an efficiency of >90 %. Ni, Co, and Mn are recovered by dilute acid leaching with efficiencies >98 %. The CTS reduction strategy is feasible for various spent cathode materials, including NCM111, NCM523, NCM622, NCM811, LiCoO₂ , and LiMn₂ O₄ . The CTS process, with its low energy consumption and potential scale application, provides an efficient and environmentally friendly way for recovering spent lithium-ion batteries.