Challenges to Future Development of Spent Lithium Ion Batteries Recovery from Environmental and Technological Perspectives

A mild and efficient closed-loop recycling strategy for spent lithium-ion battery

As lithium metal resource supply and demand stabilize and prices decrease, the efficient recovery of valuable metals other than lithium from spent lithium-ion batteries is receiving increasing attention. Currently, challenges remain in the selective lithium recovery efficiency and the high cost of regenerating valuable metal slag after lithium extraction, particularly for spent ternary cathode materials. To address these challenges, this study introduces a closed-loop recovery process for spent ternary cathode materials, employing sulfur-assisted roasting to achieve efficient lithium extraction and high-value direct regeneration of ternary leaching residues. At moderate temperatures (500 ℃), LiNixCoyMn1-x-yO2 (NCM) materials undergo a directional transformation of lithium to Li2SO4 in synergy with sulfur and oxygen, achieving a lithium leaching extraction rate of 98.91 %. Additionally, the relatively mild reaction conditions preserve the secondary spherical morphology and uniform distribution of NiCoMn-based oxide residue without introducing adverse impurities, ensuring the successful regeneration of high-value NCM cathode materials (R-NCM). The R-NCM material exhibits good discharge capacity (144.3 mA·h/g at 1 C) and relatively stable cycling performance, with a capacity retention rate of 80 % after 150 cycles. This work provides a viable pathway for the efficient and environmental-friendly pyrometallurgical closed-loop recovery of spent lithium-ion batteries.

Sustainable reprocessing of lithium iron phosphate batteries: A recovery approach using liquid-phase method at reduced temperature

Lithium iron phosphate batteries, known for their durability, safety, and cost-efficiency, have become essential in new energy applications. However, their widespread use has highlighted the urgency of battery recycling. Inadequate management could lead to resource waste and environmental harm. Traditional recycling methods, like hydrometallurgy and pyrometallurgy, are complex and energy-intensive, resulting in high costs. To address these challenges, this study introduces a novel low-temperature liquid-phase method for regenerating lithium iron phosphate positive electrode materials. By using N2H4·H2O as a reducing agent, missing Li+ ions are replenished, and anti-site defects are reduced through annealing. This process restores nearly all missing Li+ ions at 80 °C/6h. After high-temperature sintering at 700 °C/2h, the regenerated LiFePO4 matches commercial LiFePO4 in terms of anti-site defects and exhibits excellent performance with a 97 % capacity retention rate after 100 cycles at 1C. Compared to high-temperature techniques, this low-temperature liquid-phase method is simpler, safer, and more energy-efficient, offering a blueprint for reclaiming discarded LiFePO4 and similar materials.

Enhanced electrochemical discharge of Li-ion batteries for safe recycling

The recycling of spent lithium-ion batteries (LIBs) is crucial to sustainably manage resources and protect the environment as the use of portable electronics and electric vehicles (EVs) increases. However, the safe recycling of spent LIBs is challenging, as they often contain residual energy. Left untreated, this can trigger a thermal runaway and result in disasters during the recycling process. For efficient recycling, it is important to withdraw any leftover energy from LIBs, regardless of the processing method that follows the discharge. The electrochemical discharge method is a quick and inexpensive method to eliminate this hazard. This method works by immersing batteries in an aqueous inorganic salt solution to discharge LIBs completely and efficiently. Previously, research focus has been on different inorganic salt solutions that release toxic or flammable gaseous products during discharge. In contrast, we present an entirely new approach for electrochemical discharge - the utilization of an Fe(ii)-Fe(iii) redox couple electrolyte. We show that this medium can be used for efficient LIB deep discharge to a voltage of 2.0 V after rebound, a level that is low enough for safe discharge. To accomplish this, periodic discharge methods were used. In addition, no corrosion on the battery casing was observed. The pH behavior at the poles was also investigated, and it was found that without convection, gas evolution during discharge cannot be avoided. Finally, it was discovered that the battery casing material plays a vital role in electrochemical discharge, and its industrial standardization would facilitate efficient recycling.

Potential-Regulated Design for Direct Recycling of Degraded LiFePO4 Cathode

The rapid proliferation of power sources equipped with lithium-ion batteries poses significant challenges in terms of post-scrap recycling and environmental impacts, necessitating urgent attention to the development of sustainable solutions. The cathode direct regeneration technologies present an optimal solution for the disposal of degraded cathodes, aiming to non-destructively re-lithiate and straightforwardly reuse degraded cathode materials with reasonable profits and excellent efficiency. Herein, a potential-regulated strategy is proposed for the direct recycling of degraded LiFePO4 cathodes, utilizing low-cost Na2SO3 as a reductant with lower redox potential in the alkaline systems. The aqueous re-lithiation approach, as a viable alternative, not only enables the re-lithiation of degraded cathode while ignoring variation in Li loss among different feedstocks but also utilizes the rapid sintering process to restore the cathode microstructure with desirable stoichiometry and crystallinity. The regenerated LiFePO4 exhibits enhanced electrochemical performance with a capacity of 144 mA h g-1 at 1 C and a high retention of 98% after 500 cycles at 5 C. Furthermore, this present work offers considerable prospects for the industrial implementation of directly recycled materials from lithium-ion batteries, resulting in improved economic benefits compared to conventional leaching methods.

Mixed crushing and competitive leaching of all electrode material components and metal collector fluid in the spent lithium battery

Hydrometallurgy is a primary method for recovering cathode electrode materials from spent lithium-ion batteries (LIBs). Most of the current research materials are pure cathode electrode materials obtained through manual disassembly. However, the spent LIBs are typically broken as a whole during the actual industrial recycling which makes the electrode materials combined with the collector fluid. Therefore, the competitive leaching between metal collector fluid and electrode material was examined. The pyrolysis characteristics of the electrode materials were analyzed to determine the pyrolysis temperature. The electrode sheet was pyrolyzed and then crushed for competitive leaching. The effect of pyrolysis was analyzed by XPS. The competitive leaching behavior was studied based on leaching agent concentration, leaching time and leaching temperature. The composition and morphology of the residue were determined to prove the competitive leaching results by XRD-SEM. TG results showed that 500 °C was the suitable pyrolysis temperature. XPS analysis demonstrated that pyrolysis can completely remove PVDF. Li and Co were preferentially leached during the competitive leaching while the leaching rates were 90.10% and 93.40% with 50 min leaching at 70 °C. The Al and Cu had weak competitive leachability and the leaching rate was 29.10% and 0.00%. XRD-SEM analysis showed that Li and Co can be fully leached with residual Al and Cu remaining. The results showed that the mixed leaching of electrode materials is feasible based on its excellent selective leaching properties.

Research on the facile regeneration of degraded cathode materials from spent LiNi0.5Co0.2Mn0.3O2 lithium-ion batteries

Rational reusing the waste materials in spent batteries play a key role in the sustainable development for the future lithium-ion batteries. In this work, we propose an effective and facile solid-state-calcination strategy for the recycling and regeneration of the cathode materials in spent LiNi0.5Co0.2Mn0.3O2 (NCM523) ternary lithium-ion batteries. By systemic physicochemical characterizations, the stoichiometry, phase purity and elemental composition of the regenerated material were deeply investigated. The electrochemical tests confirm that the material characteristics and performances got recovered after the regeneration process. The optimal material was proved to exhibit the excellent capacity with a discharge capacity of 147.9 mAh g-1 at 1 C and an outstanding capacity retention of 86% after 500 cycles at 1 C, which were comparable to those of commercial NCM materials.

Development of a Time Projection Chamber Readout with Hybrid Pixel Sensors for Beam Monitoring

To monitor the position and profile of therapeutic carbon beams in real-time, in this paper, we proposed a system called HiBeam-T. The HiBeam-T is a time projection chamber (TPC) with forty Topmetal-II- CMOS pixel sensors as its readout. Each Topmetal-II- has 72 × 72 pixels with the size of 83 μm × 83 μm. The detector consists of the charge drift region and the charge collection area. The readout electronics comprise three Readout Control Modules and one Clock Synchronization Module. This Hibeam-T has a sensitive area of 20 × 20 cm and can acquire the center of the incident beams. The test with a continuous 80.55 MeV/u 12C6+ beam shows that the measurement resolution to the beam center could reach 6.45 μm for unsaturated beam projections.

Alkali hydroxide (LiOH, NaOH, KOH) in water: Structural and vibrational properties, including neutron scattering results

Structural and vibrational properties of aqueous solutions of alkali hydroxides (LiOH, NaOH, and KOH) are computed using quantum molecular dynamics simulations for solute concentrations ranging between 1 and 10M. Element-resolved partial radial distribution functions, neutron and x-ray structure factors, and angular distribution functions are computed for the three hydroxide solutions as a function of concentration. The vibrational spectra and frequency-dependent conductivity are computed from the Fourier transforms of velocity autocorrelation and current autocorrelation functions. Our results for the structure are validated with the available neutron data for 17M concentration of NaOH in water [Semrouni et al., Phys. Chem. Chem. Phys. 21, 6828 (2019)]. We found that the larger ionic radius [rLi+ Collapse

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Affiliation(s)

Ruru Ma Collaboratory for Advanced Computing and Simulations, University of Southern California, Los Angeles, California 90007-0242, USA
Nitish Baradwaj Collaboratory for Advanced Computing and Simulations, University of Southern California, Los Angeles, California 90007-0242, USA
Ken-Ichi Nomura Collaboratory for Advanced Computing and Simulations, University of Southern California, Los Angeles, California 90007-0242, USA
Aravind Krishnamoorthy Department of Mechanical Engineering, Texas A&M University, College Station, Texas 77843-3123, USA
Rajiv K Kalia Collaboratory for Advanced Computing and Simulations, University of Southern California, Los Angeles, California 90007-0242, USA
Aiichiro Nakano Collaboratory for Advanced Computing and Simulations, University of Southern California, Los Angeles, California 90007-0242, USA
Priya Vashishta Collaboratory for Advanced Computing and Simulations, University of Southern California, Los Angeles, California 90007-0242, USA

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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.

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 of waste lithium-ion batteries via a one-step process using a novel deep eutectic solvent

Deep eutectic solvents (DESs) possess excellent solubility and selectivity, making them suitable for extracting valuable metals and serving as a green alternative in the recycling process. This work introduces a low-viscosity DES consisting of dimethylthetin, oxalic acid, and water for the comprehensive recovery of cathode materials from LIBs. Leaching parameters such as ratio (1:1), leaching temperature (60 °C), and reaction time (15 min) for were systematically optimized, resulting in a selective separation efficiency of 99.98 % for lithium ions. Furthermore, in-situ regeneration of the precursor can be achieved during the leaching process. Charge-discharge tests indicate that the initial charge and discharge capacities of the regenerated battery are 166.8 mAh/g and 138.4 mAh/g, respectively. The DES demonstrates stability and can be easily recycled by replenishing the consumed components. This proposed strategy facilitates the reintroduction of nonrenewable resources into the supply chain and reduces the environmental impact of heavy metals, aligning with the principles of a circular economy.

Defluorination and directional conversion to light fuel by lithium synergistic vacuum catalytic co-pyrolysis for electrolyte and polyvinylidene fluoride in spent lithium-ion batteries

To overcome the drawbacks of current recycling technologies and achieve clean utilization of toxic substances in spent lithium-ion batteries, a lithium synergistic vacuum catalytic co-pyrolysis method was proposed to defluorinate electrolyte and polyvinylidene fluoride with directional conversion to light fuel. The gas chromatography-mass spectrometry results indicated, compared to the control group, that adding CaO-ZSM-5 catalyst increased the light fuel (alcohols and hydrocarbons) content of the pyrolysis gas from 61.8 % to 91.47 % under the optimal conditions (530 °C and initial pressure of 100 Pa), whereas the total proportion of esters and toxic organic compounds decreased from 32.58 % to 3.99 %. Moreover, the ethylene carbonate and hexanedinitrile content of the electrolyte was enriched to 85 % in the pyrolysis oil. Notably, fluoride was not detected in the pyrolysis oil and gas, achieving a 98.16 % defluorination rate, implying that hazardous waste was transformed to ordinary waste, thereby greatly avoiding toxic emissions to the environment. The X-ray diffraction (XRD) and scanning electron microscopy/energy-dispersive X-ray spectroscopy data indicated that fluorine was fixed in the form of CaF2. X-ray photoelectron spectroscopy and XRD analysis of the catalytic pyrolysis residue confirmed that nonferrous metals in the cathode material were converted into simple substances and oxides. Finally, possible co-pyrolysis mechanisms of the organic compounds are proposed, including Li+ generation, chain initiation, catalytic pyrolysis, and directional conversion.

Reaction-passivation mechanism driven materials separation for recycling of spent lithium-ion batteries

Development of effective recycling strategies for cathode materials in spent lithium-ion batteries are highly desirable but remain significant challenges, among which facile separation of Al foil and active material layer of cathode makes up the first important step. Here, we propose a reaction-passivation driven mechanism for facile separation of Al foil and active material layer. Experimentally, >99.9% separation efficiency for Al foil and LiNi0.55Co0.15Mn0.3O2 layer is realized for a 102 Ah spent cell within 5 mins, and ultrathin, dense aluminum-phytic acid complex layer is in-situ formed on Al foil immediately after its contact with phytic acid, which suppresses continuous Al corrosion. Besides, the dissolution of transitional metal from LiNi0.55Co0.15Mn0.3O2 is negligible and good structural integrity of LiNi0.55Co0.15Mn0.3O2 is well-maintained during the processing. This work demonstrates a feasible approach for Al foil-active material layer separation of cathode and can promote the green and energy-saving battery recycling towards practical applications.

High-efficiency recycling of spent lithium-ion batteries: A double closed-loop process

Due to the scarcity of raw materials and negative environmental effects, it is essential to selectively recover lithium and other transition metals from end-of-life lithium-ion batteries (LIBs). Here, we propose a dual closed-loop process for resource utilization of spent LIBs. As an alternative to strong inorganic acids, deep eutectic solvents (DESs) as green solvents are employed for the recycling of spent LIBs. The DES based on oxalic acid (OA) and choline chloride (ChCl) achieves efficient leaching of valued metals within a short time. Through the coordination adjustment of water, it can form high-value battery precursors directly in DES, changing wastes into valuables. Meanwhile, water as a diluent can achieve the selective separation of lithium ions via filtration. More importantly, DES can be perfectly re-generated and recycled many times, indicating that the process is cost-effective and eco-friendly. As experimental proof, the re-generated precursors were used to produce new Li(Ni_0.5Co_0.2Mn_0.3)O₂ (NCM523) button batteries. The constant current charge-discharge test revealed that the initial charge and discharge values of the re-generated cells were 177.1 and 149.5 mAh/g, respectively, corresponding to the performance of commercial NCM523 cells. The whole recycling process is clean, efficient, and environment-friendly, realizing the double closed loop of spent battery regeneration and deep eutectic solvent re-use. This fruitful research demonstrates DES has excellent potential for recycling spent LIBs and provides an efficient and eco-friendly double closed-loop solution for the sustainable re-generation of spent 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.

Extraction of precious metals from used lithium-ion batteries by a natural deep eutectic solvent with synergistic effects

As the demand for lithium-ion batteries rises, the growing quantity of waste produced from lithium-ion battery electrode materials becomes an issue of concern. We propose a novel approach for effectively extracting precious metals from cathode materials that address the problem of secondary pollution and high energy consumption that arise from the conventional wet recovery process. The method employs a natural deep eutectic solvent (NDES) composed of betaine hydrochloride (BeCl) and citric acid (CA). The leaching rates of manganese (Mn), nickel (Ni), lithium (Li), and cobalt (Co) in cathode materials may reach 99.2 %, 99.1 %, 99.8 %, and 98.8 %, respectively, due to the synergy of strong coordination ability (Cl^-) and reduction (CA) in NDES. This work avoids the use of hazardous chemicals while achieving total leaching in a short period (30 min) at a low temperature (80 °C), achieving an efficient and energy-saving aim. It reveals that NDES has a high potential for recovering precious metals from cathode materials and offers a viable, environmentally friendly method of recycling used lithium-ion batteries (LIBs).

High concentration from resources to market heightens risk for power lithium-ion battery supply chains globally

Global low-carbon contracts, along with the energy and environmental crises, have encouraged the rapid development of the power battery industry. As the current first choice for power batteries, lithium-ion batteries have overwhelming advantages. However, the explosive growth of the demand for power lithium-ion batteries will likely cause crises such as resource shortages and supply-demand imbalances. This study adopts qualitative and quantitative research methods to comprehensively evaluate the power lithium-ion battery supply and demand risks by analyzing the global material flow of these batteries. The results show that the processes from resources to market of the power lithium-ion battery industry are highly concentrated with growing trends. The proportion of the top three power lithium-ion battery-producing countries grew from 71.79% in 2016 to 92.22% in 2020, increasing by 28%. The top three power lithium-ion battery-demand countries accounted for 83.07% of the demand in 2016 and 88.16% in 2020. The increasing concentration increases the severity of the supply risk. The results also imply that different processes are concentrated within different countries or regions, and the segmentation puts the development of the power lithium-ion battery industry at significant risk. It is urgent to address this situation so that this severe risk can be ameliorated.

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.

A mechanochemical method for one-step leaching of metals from spent LIBs

A one-step system based on mechanochemical activation and the use of grape skins (GS) was proposed to recover metals from lithium-ion batteries (LIBs) cathode waste. The effects of the ball-milling (BM) speed, BM time, and quantity of added GS on the metal leaching rate were explored. The spent lithium cobalt oxide (LCO) and its leaching residue before and after mechanochemistry were characterized by SEM, BET, PSD, XRD, FT-IR, and XPS analysis. Our study shows that mechanochemistry promotes the leaching efficiency of metals from LIBs battery cathode waste by changing the cathode material properties (that is, reducing the LCO particle size (12.126 μm ∼ 0.0928 μm), increasing the specific surface area (0.123 m²/g ∼ 15.957 m²/g), enhancing the hydrophilicity and surface free energy (57.44 mN/m² ∼ 66.18 mN/m²), promoting the generation of mesoporous structures, refining grains, disrupting the crystal structure, and increasing the microscopic strain, while deflecting the binding energy of the metal ions). A green, efficient and environmentally friendly process for the harmless and resource-friendly treatment of spent LIBs has been developed in this study.

Selective Extraction of Critical Metals from Spent Lithium-Ion Batteries

Selective and highly efficient extraction technologies for the recovery of critical metals including lithium, nickel, cobalt, and manganese from spent lithium-ion battery (LIB) cathode materials are essential in driving circularity. The tailored deep eutectic solvent (DES) choline chloride-formic acid (ChCl-FA) demonstrated a high selectivity and efficiency in extracting critical metals from mixed cathode materials (LiFePO₄:Li(NiCoMn)_1/3O₂ mass ratio of 1:1) under mild conditions (80 °C, 120 min) with a solid-liquid mass ratio of 1:200. The leaching performance of critical metals could be further enhanced by mechanochemical processing because of particle size reduction, grain refinement, and internal energy storage. Furthermore, mechanochemical reactions effectively inhibited undesirable leaching of nontarget elements (iron and phosphorus), thus promoting the selectivity and leaching efficiency of critical metals. This was achieved through the preoxidation of Fe and the enhanced stability of iron phosphate framework, which significantly increased the separation factor of critical metals to nontarget elements from 56.9 to 1475. The proposed combination of ChCl-FA extraction and the mechanochemical reaction can achieve a highly selective extraction of critical metals from multisource spent LIBs under mild conditions.

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.

A perspective on the recovery mechanisms of spent lithium iron phosphate cathode materials in different oxidation environments

Oxidative extraction has become an economically viable option for recycling lithium (Li) from spent lithium iron phosphate (LiFePO₄) batteries. In this study, the releases behaviour of Li from spent LiFePO₄ batteries under different oxidizing conditions was investigated with sodium hypochlorite (NaClO) as the solid oxidant. We revealed that, due to the intervention of graphitic carbon, the generated species of Li in mechanochemical oxidation (NaClO:LiFePO₄ at a molar ratio of 2:1, 5 min, and 600 rpm) was lithium carbonate (Li₂CO₃). The graphite layer provided a channel for the conversion of Li species released by mechanochemical oxidation. While in hydrometallurgical oxidation (NaClO:LiFePO₄ at a molar ratio of 2:1 and 12.5 min), the presence of hydrogen species led to the formation of lithium chloride (LiCl). Moreover, life cycle assessment (LCA) demonstrated that for recycling 1.0 kg of spent LiFePO₄ batteries, mechanochemical and hydrometallurgical oxidation could reduce carbon footprints by 2.81 kg CO₂ eq and 2.88 kg CO₂ eq, respectively. Our results indicate that the oxidative environment determines the release pathway of Li from the spent LiFePO₄ cathode material, thereby regulating the product forms of Li and environmental impacts. This study can provide key technical guidance for Li recycling from spent LiFePO₄ batteries.

Challenges in Recycling Spent Lithium-Ion Batteries: Spotlight on Polyvinylidene Fluoride Removal

In the recycling of retired lithium-ion batteries (LIBs), the cathode materials containing valuable metals should be first separated from the current collector aluminum foil to decrease the difficulty and complexity in the subsequent metal extraction. However, strong the binding force of organic binder polyvinylidene fluoride (PVDF) prevents effective separation of cathode materials and Al foil, thus affecting metal recycling. This paper reviews the composition, property, function, and binding mechanism of PVDF, and elaborates on the separation technologies of cathode material and Al foil (e.g., physical separation, solid-phase thermochemistry, solution chemistry, and solvent chemistry) as well as the corresponding reaction behavior and transformation mechanisms of PVDF. Due to the characteristic variation of the reaction systems, the dissolution, swelling, melting, and degradation processes and mechanisms of PVDF exhibit considerable differences, posing new challenges to efficient recycling of spent LIBs worldwide. It is critical to separate cathode materials and Al foil and recycle PVDF to reduce environmental risks from the recovery of retired LIBs resources. Developing fluorine-free alternative materials and solid-state electrolytes is a potential way to mitigate PVDF pollution in the recycling of spent LIBs in the EV era.

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.

Facile separation and regeneration of LiFePO4 from spent lithium-ion batteries via effective pyrolysis and flotation: An economical and eco-friendly approach

The facile recycling of spent lithium-ion batteries (LIBs) has attracted much attention because of its great significance to the environmental protection and resource utilization. Hydrometallurgical process is the most common method for recycling spent LIBs, but it is difficult to economically recover spent LiFePO₄ batteries, because of the complicated metal separation process and low added value of its products. Herein, a novel and facile approach has been developed to achieve the direct regeneration of LiFePO₄ from spent LIBs. By employing a flotation process after effective pyrolysis, it is found that 91.57% of LiFePO₄ can be recovered from spent LIBs. Different surface hydrophobicity of cathode and anode active materials could be achieved via the selective adsorption of causticized soluble starch on the surfaces of spent LiFePO₄, which effectively enhances the separation performance in flotation process. The recovered LiFePO₄ barely contains metal impurities, which can be directly regenerated as new LiFePO₄ materials with the first discharge capacity of 161.37 mAh/g, and their capacity retention is as high as 97.53% after 100 cycles at 0.2C. A technology assessment and economic evaluation indicate the developed regeneration approach of LiFePO₄ is environmentally and economically feasible, which avoids the complex element separation process and achieves the facile recycling of spent LiFePO₄.

Applications of Spent Lithium Battery Electrode Materials in Catalytic Decontamination: A Review

For a large amount of spent lithium battery electrode materials (SLBEMs), direct recycling by traditional hydrometallurgy or pyrometallurgy technologies suffers from high cost and low efficiency and even serious secondary pollution. Therefore, aiming to maximize the benefits of both environmental protection and e-waste resource recovery, the applications of SLBEM containing redox-active transition metals (e.g., Ni, Co, Mn, and Fe) for catalytic decontamination before disposal and recycling has attracted extensive attention. More importantly, the positive effects of innate structural advantages (defects, oxygen vacancies, and metal vacancies) in SLBEMs on catalytic decontamination have gradually been unveiled. This review summarizes the pretreatment and utilization methods to achieve excellent catalytic performance of SLBEMs, the key factors (pH, reaction temperature, coexisting anions, and catalyst dosage) affecting the catalytic activity of SLBEM, the potential application and the outstanding characteristics (detection, reinforcement approaches, and effects of innate structural advantages) of SLBEMs in pollution treatment, and possible reaction mechanisms. In addition, this review proposes the possible problems of SLBEMs in practical decontamination and the future outlook, which can help to provide a broader reference for researchers to better promote the implementation of “treating waste to waste” strategy.

Leaching valuable metals from spent lithium-ion batteries using the reducing agent methanol

When considering resource shortages and environmental pressures, salvaging valuable metals from the cathode materials of spent lithium-ion batteries (LIBs) is a very promising strategy to realize the green and sustainable development of batteries. The reductive acid leaching of valuable metals from cathode materials using methanol as a reducing agent was studied. The results show that the leaching efficiencies of Co and Li are 99% under optimal leaching conditions. The leaching kinetics of cathode materials in a H₂SO₄-methanol system indicate that the leaching of Co and Li is controlled by diffusion, with activation energies of 69.98 and 10.78 kJ/mol, respectively. Detailed analysis of the leaching reaction mechanism indicates that methanol is ultimately transformed into formic acid through a two-step process to further enhance leaching. No side reactions occur during leaching. Methanol can be a sustainable alternative for the reductive acid leaching of valuable metals from spent LIBs due to its high efficiency, application maturity, environmental friendliness, and low cost.

Comparison of Electric Vehicle Lithium-Ion Battery Recycling Allocation Methods

Power lithium-ion batteries (LIBs) are an important component of carbon neutrality in the transportation sector. The rapid growth of the LIB recycling industry is driven by various factors, such as resource scarcity. As a process interacting upstream and downstream, LIB recycling must consider the impact of the application of modeling approaches on the allocation of environmental benefits and burdens, especially at a time when carbon emissions are highly correlated with profit. In this study, seven allocation methods were chosen and applied to the production and multiple recycling process of typical LIB on the same data basis. The application of different allocation methods produced very disparate allocation results, and the conclusions of previous studies comparing the environmental performance of battery types need to be revisited. The life-cycle assessment (LCA) results should be interpreted with caution due to the impact of the allocation methods. Furthermore, a multi-indicator qualitative analysis based on product and process characteristics compares the applicability of the allocation methods to different aspects of LIB recycling. Relevant product standards for batteries should consider the characteristics of different methods and recommend a specific allocation method for the LCA community to employ in time to ensure that relevant studies are representative and comparable.

Performance of toluene oxidation on different morphologies of α-MnO2 prepared using manganese-based compound high-selectively recovered from spent lithium-ion batteries

The proper disposals of spent lithium-ion batteries (LIBs) and volatile organic compounds (VOCs) both have a significant impact on the environment and human health. In this work, different morphologies of α-MnO₂ catalysts are synthesized using a manganese-based compound as the precursor which is high-selectively recovered from spent lithium-ion ternary batteries. Different synthesis methods including the co-precipitation method, hydrothermal method, and impregnation method are used to prepare different morphologies of α-MnO₂ catalysts and their catalytic activities of toluene oxidation are investigated. Experimental results show that MnO₂-HM-140 with stacked nanorods synthesized using the hydrothermal method exhibits the best catalytic performance of toluene oxidation (T₉₀ of 226 °C under the WHSV of 60,000 mL g^-1·h^-1), which could be attributed to its better redox ability at low temperature and much more abundant adsorbed oxygen species at low temperature. The adsorption abilities of toluene and the replenish rate of surface lattice oxygen can be enhanced due to the increase of oxygen vacancies on the surface of MnO₂-HM-140. Furthermore, the results of in-situ DRIFTS and TD/GC-MS imply that benzoate species are the main intermediate groups and then the reaction pathway of toluene oxidation on the surface of MnO₂-HM-140 is proposed.

Applications of crushing and grinding-based treatments for typical metal-containing solid wastes: Detoxification and resource recovery potentials

Metal-containing solid wastes can induce serious environmental pollution if managed improperly, but contain considerable resources. The detoxification and resource recoveries of these wastes are of both environmental and economic significances, being indispensable for circular economy. In the past decades, attempts have been made worldwide to treat these wastes. Crushing and grinding-based treatments have been increasingly applied, the operating apparatus and parameters of which depend on the waste type and treatment purpose. Based on the relevant studies, the applications of crushing and grinding on four major types of solid wastes, namely spent lithium-ion batteries (LIBs) cathode, waste printed circuit boards (WPCBs), incineration bottom ash (IBA), and incineration fly ash (IFA) are here systematically reviewed. These types of solid wastes are generated in increasing amounts, and have the potentials to release various organic and inorganic pollutants. Despite of the widely different texture, composition, and other physicochemical properties of the solid wastes, crushing and grinding have been demonstrated to be universally applicable. For each of the four wastes, the technical route that involving crushing and grinding is described with the advantages highlighted. The crushing and grinding serve either mainstream or auxiliary role in the processing of the solid wastes. This review summarizes and highlights the developments and future directions of crushing and grinding-based treatments.

Are Ingested or Inhaled Microplastics Involved in Nonalcoholic Fatty Liver Disease?

Nonalcoholic fatty liver disease (NAFLD) has emerged as the predominant cause of chronic liver injury; however, the mechanisms underlying its progression have not been fully elucidated. Pathophysiological studies have stated that NAFLD is significantly influenced by dietary and environmental factors that could participate in the development of NAFLD through different mechanisms. Currently, "plastic pollution" is one of the most challenging environmental problems worldwide since several plastics have potential toxic or endocrine disputing properties. Specifically, the intake of microplastics (MPs) and nanoplastics (NPs) in water or diet and/or the inhalation from suspended particles is well established, and these particles have been found in human samples. Laboratory animals exposed to MPs develop inflammation, immunological responses, endocrine disruptions, and alterations in lipid and energy metabolism, among other disorders. MPs additives also demonstrated adverse reactions. There is evidence that MPs and their additives are potential "obesogens" and could participate in NAFLD pathogenesis by modifying gut microbiota composition or even worsen liver fibrosis. Although human exposure to MPs seems clear, their relationship with NAFLD requires further study, since its prevention could be a possible personalized therapeutic strategy. Adequate mitigation strategies worldwide, reducing environmental pollution and human exposure levels of MPs, could reduce the risk of NAFLD.

Recovery of Valuable Metals from Cathode—Anode Mixed Materials of Spent Lithium-Ion Batteries Using Organic Acids

Spent lithium-ion batteries (LIBs) contain a large number of valuable metals and will be an important strategic resource in the future. Therefore, recycling is extremely important. In this work, acetic acid and hydrogen peroxide were used as leaching agents to recover valuable metals (lithium, cobalt, nickel, manganese, and aluminum) from cathode and anode materials (LiCoO2, LiAl0.2Co0.8O2, and C) of spent LIBs. The leaching solution and leaching residue were analyzed by inductive plasma optical emission spectrometry (ICP-OES), scanning electron microscopy (SEM), and X-ray diffraction (XRD). The optimum experimental conditions were obtained by changing the concentration of acetic acid, solid–liquid ratio, reaction temperature, time, and the concentration of hydrogen peroxide reducing agent. Under the experimental conditions of 2 M acetic acid, 4.0 vol.% H2O2, 20 g/L, and 70 °C for 40 min, the leaching rates of lithium, cobalt, nickel, manganese, and aluminum reached 98.56%, 94.61%, 96.39%, 97.97%, and 94.7%, respectively. This hydrometallurgical process is simple and environmentally friendly and maximizes the recovery of valuable metals from spent LIBs.

Porous Carbons Derived from Desiliconized Rice Husk Char and Their Applications as an Adsorbent in Multivalent Ions Recycling for Spent Battery

Recycling of spent lithium-ion batteries (LIBs) has attracted increasing attentions recently on account of continuous growth demand for corresponding critical metals/materials and environmental requirement of solid waste disposal. In this work, rice husk as one of the most abundant renewable fuel materials in the world was used to prepare rice husk char (RC) and applied to recycle multivalent ions in waste water from hydrometallurgical technology dispose of spent LIBs. Rice husk char with specific surface area and abundant pores was obtained via pickling and desilication process (DPRC). The structural characterization of the obtained rice husk char and its adsorption capacity for multivalent ions in recycled batteries were studied. XRD, TEM, SEM, Raman, and BET were used for the characterization of the raw and the modified samples. The results show rice husk chars after desilication has more flourishing pore structure and larger pore size about 50–60 nm. Meanwhile, after desilication, the particle size of rice husk char decreased to 31.392 μm, and the specific surface area is about 402.10 m2/g. Its nitrogen adsorption desorption curve (BET) conforms to the type IV adsorption isotherm with H3 hysteresis ring, indicating that the prepared rice husk char is a mesoporous material. And the adsorption capacity of optimized DPRC for Ni, Co, and Mn ions is 7.00 mg/g, 4.84 mg/g, and 2.67 mg/g, respectively. It also demonstrated a good fit in the Freundlich model for DPRC-600°C, and a possible adsorption mechanism is proposed. The study indicates biochar materials have great potential as an adsorbent to recover multivalent ions from spent batteries.

Recycling of valuable metals from spent cathode material by organic pyrolysis combined with in-situ thermal reduction

From the perspective of environmental protection and resource recovery, recycling of spent lithium-ion batteries is a meaningful process. In this study, the removal of organics, liberatioin of electrode material, and reduction of high valence transition metal, as the key points in recycling efficiency of valuable metals, have been firstly achieved simultaneously by low temperature heat treatment recycling process. Pyrolysis characteristics of organics, phase transition behavior of spent cathode material and the thermal reduction mechanism were evaluated in the meantime. Results demonstrate that organics can be removed and the liberation of electrode materials can be improved by pyrolysis. High-valence transition metals in cathode materials are synchronously reduced to CoO, NiO, MnO, Ni, and Co based on the reducing action of organics, aluminum foil and conductive additives. At the same time, Li element exists in the form of Li₂CO₃, LiF and aluminum-lithium compound that can be recycled by water-leaching in the water impact crushing process while transition metals can be recycled by acid leaching without reducing agents. 81.26% of Li can be recycled from water-leaching process while the comprehensive recovery rate of Ni, Co, Mn is 92.04%, 93.01%, 92.21%, respectively. This study may provide an environmentally-friendly recycling flowchart of spent lithium-ion batteries.

Sustainably recycling spent lithium-ion batteries to prepare magnetically separable cobalt ferrite for catalytic degradation of bisphenol A via peroxymonosulfate activation

A selective separation-recovery process based on tuning organic acid was proposed to the resource recycling of spent lithium-ion batteries (LIBs) for the first time. The low-cost preparation of CoFe₂O₄, reuse of waste acid and recovery of Li can be realized in this process, simultaneously. Li and Co in spent LIBs can be leached efficiently using citric acid as a leaching agent, and separated effectively from leaching solution by tuning oxalic acid content. The results from the characterizations of the prepared CoFe₂O₄ (CoFe₂O₄-LIBs) show that it possesses higher ratio of Co(II)/Co(III) and Fe(II)/Fe(III), larger surface specific area and more number of acid sites in comparison with pure CoFe₂O₄. Besides, CoFe₂O₄-LIBs was used to activate peroxymonosulfate (PMS) for the degradation of bisphenol A (BPA). Interestingly, its degradation performance is superior to that of pure CoFe₂O₄ and the related Co-based catalysts. The excellent degradation performance can be maintained in presence of inorganic ions (e.g., Cl^-, HCO₃^-, H₂PO₄^- and NO₃^-) with high concentration or humic acid. Moreover, surface-bound SO₄^∙- is considered as the main reactive species for the degradation of BPA. More importantly, CoFe₂O₄-LIBs can be readily recycled by using an external magnet and own superior ability of regeneration.

Environmental impacts of hydrometallurgical recycling and reusing for manufacturing of lithium-ion traction batteries in China

Recycling lithium-ion batteries from electric vehicles is considered an important way to tackle the future supply risks of virgin materials, but the actual environmental impact of traction battery recycling is controversial. This study conducted a process-based life cycle assessment to quantify the environmental impacts of hydrometallurgical recycling of two common lithium-ion traction batteries (lithium nickel manganese cobalt oxide and lithium iron phosphate battery) and reusing materials in their manufacturing in China. The results show that recycling can cause net environmental benefits of the two traction battery types for the considered impact categories, but the net benefits for direct recycling technology are higher because of fewer requirements of chemicals and energy. Reusing recovered materials in battery manufacturing would reduce the impacts in comparison to no recycling, but the reduction potential of greenhouse gas emission and energy demand is not significant. Sensitivity analysis shows that recycling benefits are highly dependent on recovering efficiency and electricity used for manufacturing and recycling. Comprehensive management strategies are necessary to improve the end-of-life traction battery management, such as using carbon-free energy sources, designing batteries with less metal, and developing recycling technology using fewer chemicals. This study contributes by offering transparent life cycle inventory for hydrometallurgical recycling lithium-ion traction batteries and providing scientific knowledge to improve their sustainable management.

Coupling regeneration strategy of lithium-ion electrode materials turned with naphthalenedisulfonic acid

The resource exhaustion and environmental assessment driven by sustainable development make recycle of spent LIBs urgent to be achieved. However, the conventional recycling processes are quite complicated in terms of the tedious steps and secondary contamination. In this paper, hydrosoluble naphthalenedisulfonic acid is firstly proposed to selectively extract valuable metals (Co and Li) for the regeneration of battery materials. Lithium is selectively recovered as lithium enriched solution with a high yield of 99%, while 96.6% cobalt remains in a complex-precipitate benefited from the high acidity and coordination role of naphthalenedisulfonic acid. The leaching of Li fits well with the logarithmic rate law model with an activation energy of 32.42 kJ/mol. Additionally, the regenerated lithium-ion battery active materials (Co₃O₄ anode and LiCoO₂ cathode) prepared from the cobalt complex-precipitate and lithium-enriched solution exhibit excellent discharged-charged performances and rate capability. This feasible strategy assisted by multifunctional naphthalenedisulfonic acid may offer an alternative option for the simultaneous recovery of Li and Co and the rational resource utilization of spent lithium-ion batteries.

Efficient separation of aluminum foil from mixed-type spent lithium-ion power batteries

The disposal of spent lithium-ion power batteries (LIBs) has become an important research topic owing to the booming market for electric vehicles. However, the recovery efficiency of the alkaline solution and organic solvent methods currently used to separate Al foil from cathode materials still has room for improvement. The insufficient separation of Al foil and complexity of the battery types present obstacles to the extraction of valuable metals using simple processes. In this study, an efficient approach is developed to separate the Al foil in mixed-type spent LIBs (M-LIBs), namely, LiNi_xCo_yMn_zO₂ (NCM), LiFePO₄ (LFP), and LiMn₂O₄ (LMO) LIBs, by controlled pyrolysis. Hundred percent of the Al foil was recovered at the temperature of 450 °C, holding time of 60 min, and heating rate of 10 °C/min. The purity of Al in the recovered foil was 99.41 %, 99.83 % and 99.92 %, and the recovery efficiency of the active cathode materials was 96.01 %, 99.80 % and 99.15 % for NCM, LFP and LMO, respectively, without the loss of active cathode materials. The obtained active cathode materials exhibited a favorable crystalline structure, and the average particle diameter was reduced from 300.497 to 24.316 μm with a smaller and looser morphology. The process could be well fitted with the Friedman differential equation, and the correlation coefficients were higher than 0.99. The efficient separation could be attributed to the complete rupture of long chain -(CH₂CF₂)-_n bonds in the poly (vinylidene difluoride) (PVDF) binder, which resulted in the formation of HF, trifluorobenzene, alkanes, and gaseous single molecule CH₂CF₂. Therefore, this work potentially provides an alternative approach for the efficient separation of Al foil in M-LIBs, thereby simplifying the process and achieving lower cost, reduced loss of valuable metals, and higher recovery efficiency.

Assessment of end-of-life electric vehicle batteries in China: Future scenarios and economic benefits

A better understanding of the waste of end-of-life batteries from electric vehicles (EVs) is a basis for their sustainable management. This study aims to estimate the waste of end-of-life EV batteries during 2006-2040 in China and to analyze the opportunities and challenges of subsequent utilization, based on a developed numerical model, real market data, and elaborately developed scenarios. The result shows that end-of-life batteries would increase from 0.1 to 7.8 thousand tons during 2012-2018, and then to 1500-3300 thousand tons in 2040. Of the waste streams, around 50% are estimated to be metal materials, representing great opportunities for battery recycling for material recovery. Economically, battery recycling for energy storage is estimated to create more economic benefits compared with that for material recovery solely (147.8 versus 76.9 billion US dollars). However, the supply of end-of-life batteries can hardly meet the demand for renewable energy storage in the near future, and a spatial mismatch of the supply and demand of energy storage capacity exists between the eastern and western regions in China. Accordingly, this study highlights national coordination for the rational layout of the collection, disassembly, and remanufacture facilities for the second use of end-of-life EV batteries in China.

Highly efficient selective recovery of lithium from spent lithium-ion batteries by thermal reduction with cheap ammonia reagent

The rapid development of new energy technology leads to explosive growth of lithium-ion batteries (LIBs) industry which greatly alleviates the problems of environmental pollution and energy shortage. However, how to realize resource circulation of critical metals including lithium (Li) and cobalt (Co) becomes the new problem of LIBs industry. This paper proposes an improved thermal reduction technology to efficiently recycle Li and Co from spent LIBs, where cheap urea is applied as the only additive to provide ammonia (NH₃). By thermal reduction, LiCoO₂ was thermally reduced into water-soluble lithium carbonate and water-insoluble cobalt metal Under the optimal conditions, 99.96% Li with nearly 100% selectivity was obtained by water leaching. More importantly, the concept of "oxygen elements removal (OER)" was proposed to explain the metal extraction from spent LIBs, which could help to describe the reaction mechanism as O-cage digestion mechanism. Furthermore, metal extraction from spent LIBs was re-understood as "seeking an applicable reductant", which provided a fresh perspective for understanding Li selective recovery. These concepts and findings can provide some inspiration for metal recovery from spent LIBs.

The Electrochemical Mechanism of Preparing Mn from LiMn2O4 in Waste Batteries in Molten Salt

The electrochemical reduction mechanism of Mn in LiMn2O4 in molten salt was studied. The results show that in the NaCl-CaCl2 molten salt, the process of reducing from Mn (IV) to manganese is: Mn (IV)→Mn (III)→Mn (II)→Mn. LiMn2O4 reacts with molten salt to form CaMn2O4 after being placed in molten salt for 1 h. The reaction of reducing CaMn2O4 to Mn is divided into two steps: Mn (III)→Mn (II)→Mn. The results of constant voltage deoxidation experiments under different conditions show that the intermediate products of LiMn2O4 reduction to Mn are CaMn2O4, MnO, and (MnO)x(CaO)(1−x). As the reaction progresses, x gradually decreases, and finally the Mn element is completely reduced under the conditions of 3 V for 9 h. The CaO in the product can be removed by washing the sample with deionized water at 0 °C.

Highly efficient re-cycle/generation of LiCoO2 cathode assisted by 2-naphthalenesulfonic acid

The explosively growing demand for electrical energy is generating a great deal of spent lithium-ion batteries (LIBs). Therefore, a simple and effective strategy for the sustainable recycling of used batteries is urgently needed to minimize chemical consumption and to reduce the associated environmental pollution. In this work, 2-naphthalenesulfonic acid is innovatively proposed for the highly-selective recovery of valuable metals. Impressively, lithium and cobalt are simultaneously separated through a single-step process, in which 99.3% of lithium is leached out as Li⁺ enriched solutions while 99% of cobalt is precipitated as cobalt-naphthalenesulfonate. The obtained lithium enriched solutions are recovered as Li₂CO₃. The cobalt-naphthalenesulfonate with high purity (99%) is ready to be transformed into Co₃O₄, and then generated into LiCoO₂ by reacting with the above-obtained Li₂CO₃. The cathode material LiCoO₂ with micro/nanostructures exhibits excellent electrochemical properties. Characterization results confirm the coordination structure of the extracted cobalt complex (Co(NS)2•6H₂O). Finally, compared to other selective metal extraction techniques, this strategy avoids additional separation and purification processes, thus improving the recycling efficiency. Overall, this route can be extended to selectively extract valuable metals from other types of cathode materials in spent LIBs as a sustainable approach.