A sustainable process for the recovery of valuable metals from spent lithium-ion batteries

Toward Circular Energy: Exploring Direct Regeneration for Lithium-Ion Battery Sustainability

Lithium-ion batteries (LIBs) are rapidly developing into attractive energy storage technologies. As LIBs gradually enter retirement, their sustainability is starting to come into focus. The utilization of recycled spent LIBs as raw materials for battery manufacturing is imperative for resource and environmental sustainability. The sustainability of spent LIBs depends on the recycling process, whereby the cycling of battery materials must be maximized while minimizing waste emissions and energy consumption. Although LIB recycling technologies (hydrometallurgy and pyrometallurgy) have been commercialized on a large scale, they have unavoidable limitations. They are incompatible with circular economy principles because they require toxic chemicals, emit hazardous substances, and consume large amounts of energy. The direct regeneration of degraded electrode materials from spent LIBs is a viable alternative to traditional recycling technologies and is a nondestructive repair technology. Furthermore, direct regeneration offers advantages such as maximization of the value of recycled electrode materials, use of sustainable, nontoxic reagents, high potential profitability, and significant application potential. Therefore, this review aims to investigate the state-of-the-art direct LIB regeneration technologies that can be extended to large-scale applications.

Toward Sustainable All Solid-State Li-Metal Batteries: Perspectives on Battery Technology and Recycling Processes

Lithium (Li)-based batteries are gradually evolving from the liquid to the solid state in terms of safety and energy density, where all solid-state Li-metal batteries (ASSLMBs) are considered the most promising candidates. This is demonstrated by the Bluecar electric vehicle produced by the Bolloré Group, which is utilized in car-sharing services in several cities worldwide. Despite impressive progress in the development of ASSLMBs, their avenues for recycling them remain underexplored, and combined with the current explosion of spent Li-ion batteries, they should attract widespread interest from academia and industry. Here, the potential challenges of recycling ASSLMBs as compared to Li-ion batteries are analyzed and the current progress and prospects for recycling ASSLMBs are summarized and analyzed. Drawing on the lessons learned from Li-ion battery recycling, it is important to design sustainable recycling technologies before ASSLMBs gain widespread market adoption. A battery-recycling-oriented design is also highlighted for ASSLMBs to promote the recycling rate and maximize profitability. Finally, future research directions, challenges, and prospects are outlined to provide strategies for achieving sustainable development of ASSLMBs.

Direct recycling of spent Li-ion batteries: Challenges and opportunities toward practical applications

With the exponential expansion of electric vehicles (EVs), the disposal of Li-ion batteries (LIBs) is poised to increase significantly in the coming years. Effective recycling of these batteries is essential to address environmental concerns and tap into their economic value. Direct recycling has recently emerged as a promising solution at the laboratory level, offering significant environmental benefits and economic viability compared to pyrometallurgical and hydrometallurgical recycling methods. However, its commercialization has not been realized in the terms of financial feasibility. This perspective provides a comprehensive analysis of the obstacles that impede the practical implementation of direct recycling, ranging from disassembling, sorting, and separation to technological limitations. Furthermore, potential solutions are suggested to tackle these challenges in the short term. The need for long-term, collaborative endeavors among manufacturers, battery producers, and recycling companies is outlined to advance fully automated recycling of spent LIBs. Lastly, a smart direct recycling framework is proposed to achieve the full life cycle sustainability of LIBs.

Comparative life cycle analysis of critical materials recovery from spent Li-ion batteries

The development of new generations of electric vehicles is expected to drive the growth of lithium-ion batteries in the global market. Life Cycle Assessment (LCA) method was utilized in this study to evaluate the environmental impacts of various hydrometallurgical processes in critical materials recovery from lithium-ion battery (LIB) cathode powder. The main objective of this work was to fill the knowledge gap regarding the environmental sustainability of various processes in LIB recycling and to generate a comprehensive comparison of the environmental burdens caused by numerous hydrometallurgical methods. According to this investigation, leaching with acetic acid, formic acid, maleic acid, and DL-malic acid demonstrates lower environmental impacts compared to lactic acid, ascorbic acid, succinic acid, citric acid, trichloroacetic acid, and tartaric acid. Among inorganic acids, nitric acid and hydrochloric acid show higher environmental impacts compared to sulfuric acid. Furthermore, the results of this study indicate that leaching with some organic acids such as citric, succinic, ascorbic, trichloroacetic, and tartaric acids leads to higher negative environmental impacts in most environmental categories compared to inorganic acids like sulfuric and hydrochloric acid. Therefore, not all organic acids utilized in the leaching of critical and strategic materials from cathode powder can enhance environmental sustainability in the recycling process. The results of the solvent extraction study as a downstream process of leaching show that sodium hydroxide, organic reagents, and kerosene have the highest environmental impact among all inputs in this process. Generally, solvent extraction has a greater environmental impact compared to the leaching process.

Highly Efficient Recovery and Recycling of Cobalt from Spent Lithium-Ion Batteries Using an N-Methylurea-Acetamide Nonionic Deep Eutectic Solvent

The growing demand for lithium-ion batteries (LiBs) for the electronic and automobile industries combined with the limited availability of key metal components, in particular cobalt, drives the need for efficient methods for the recovery and recycling of these materials from battery waste. Herein, we introduce a novel and efficient approach for the extraction of cobalt, and other metal components, from spent LiBs using a nonionic deep eutectic solvent (ni-DES) comprised of N-methylurea and acetamide under relatively mild conditions. Cobalt could be recovered from lithium cobalt oxide-based LiBs with an extraction efficiency of >97% and used to fabricate new batteries. The N-methylurea was found to act as both a solvent component and a reagent, the mechanism of which was elucidated.

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.

Analysis of Lanthanum and Cobalt Leaching Aimed at Effective Recycling Strategies of Solid Oxide Cells

Lanthanum and cobalt are Critical Raw Materials and components of Solid Oxide Cells—SOCs electrodes. This review analyses lanthanum and cobalt leaching from waste materials (e-waste, batteries, spent catalysts), aiming to provide a starting point for SOC recycling, not yet investigated. The literature was surveyed with a specific interest for leaching, the first phase of hydrometallurgy recycling. Most references (86%) were published after 2012, with an interest higher (85%) for cobalt. Inorganic acids were the prevailing (>80%) leaching agents, particularly for lanthanum, while leaching processes using organic acids mostly involved cobalt. The experimental conditions adopted more diluted organic acids (median 0.55 M for lanthanum and 1.4 M for cobalt) compared to inorganic acids (median value 2 M for both metals). Organic acids required a higher solid to liquid ratio (200 g/L), compared to inorganic ones (100 g/L) to solubilize lanthanum, while the opposite happened for cobalt (20 vs. 50 g/L). The process temperature didn’t change considerably with the solvent (45–75 °C for lanthanum, and 75–88 °C for cobalt). The contact time was higher for lanthanum than for cobalt (median 3–4 h vs. 75–85 min). Specific recycling processes are crucial to support SOCs value chain in Europe, and this review can help define the existing challenges and future perspectives.

Critical Evaluation of the Potential of Organic Acids for the Environmentally Friendly Recycling of Spent Lithium-Ion Batteries

The need to recover valuable metals from spent lithium-ion batteries (LIBs) is undisputed. However, the environment and the climate are also affected by emissions from the recycling processes. Therefore, the call for environmentally friendly recycling methods is currently louder than ever. In the field of hydrometallurgical recovery of metals from spent LIBs, inorganic acids have so far proved to be an effective, but environmentally problematic, leaching agent, since the pollution of wastewater by high salt loads and the emission of toxic gases cannot be avoided. This has recently led to a trend towards the application of organic acids, as these have significantly more environmentally friendly properties. In order to continue this approach, and to improve it even further from an environmental point of view, this work focuses on the utilization of low leaching temperatures in combination with organic acids for the recovery of valuable metals from spent lithium-ion batteries. This can drastically reduce the required energy demand. Furthermore, attention is paid to higher (50–100 g·L−1) solid-liquid ratios, which are indispensable, especially with regard to the economic establishment of the tested process. The experimental verification of the feasibility using citric, oxalic, and formic acid showed the possibility of an efficient recovery of cobalt, nickel, and lithium. In particular, citric acid in combination with hydrogen peroxide as a reducing agent appears to be a suitable and environmentally friendly alternative to classical inorganic acids, even at low process temperatures, for the hydrometallurgical recycling of lithium-ion batteries.

Investigation of the Physico-Chemical Properties of the Products Obtained after Mixed Organic-Inorganic Leaching of Spent Li-Ion Batteries

Lithium-ion batteries are currently one of the most important mobile energy storage units for portable electronics such as laptops, tablets, smartphones, etc. Their widespread application leads to the generation of large amounts of waste, so their recycling plays an important role in environmental policy. In this work, the process of leaching with sulfuric acid for the recovery of metals from spent Li-ion batteries in the presence of glutaric acid and hydrogen peroxide as reducing agents is presented. Experimental results indicate that glutaric-acid application improves the leaching performance compared to the use of just hydrogen peroxide under the same conditions. Obtained samples of leaching residues after mixed inorganic-organic leaching were characterized with Scanning Electron Microscopy, Fourier Transform Infrared Spectroscopy, and X-ray diffraction.

Countercurrent leaching of Ni, Co, Mn, and Li from spent lithium-ion batteries

This study focuses on a countercurrent leaching process (CLP) for the dissolution of high-value metals from cathode active material of spent lithium-ion batteries (LIBs). Its main aim is to improve the effective utilization of acid during leaching and allow for the continuous operation of the entire CLP by adjusting the process parameters. The overall recovery of lithium (Li), cobalt (Co), nickel (Ni), and manganese (Mn) was 98%, 95%, 95%, and 92%, respectively; the acid utilization of the leaching process exceeded 95% under optimum conditions. The optimum conditions for first stage leaching were 70 g/L solid-liquid (S/L) ratio at 40°C for 30 minutes, and 2.0 M sulfuric acid, 100 g/L S/L ratio, 7 g/L starch, at 85°C for 120 minutes for second stage leaching. After five bouts of circulatory leaching, more than 98% Li, 95% Co, 95% Ni, and 92% Mn were leached under the same leaching conditions. Furthermore, we introduced the Avrami equation to describe metal leaching kinetics from spent LIBs, and determined that the second stage leaching process was controlled by the diffusion rate. In this way, Li, Ni, Co, and Mn can be recovered efficiently and the excess acid in the leachate can be reused in this hydrometallurgical process, potentially offering economic and environmental benefits.

Study on the process of harmless treatment of residual electrolyte in battery disassembly

Residual electrolyte is the main pollution source in the lithium ion battery disassembly process. A practical detoxified approach is studied using the lithium hexafluorophosphate in the decommissioned power battery with dimethyl carbonate as a solvent. The pH measurement, Fourier transform infrared spectroscopy, micromorphology and phase structure characterization techniques showed that the process in this study is capable of removing lithium hexafluorophosphate from decommissioned power batteries, while controlling the proper ratio of NaOH can also completely precipitate F^- into CaF₂ crystal and allows recycling of the organic solvents. This process scheme of residual electrolyte treatment effectively reduces environmental pollution during the decommissioned power batteries recycling process, and has the benefit of resource reuse for valuable elements.

Recovery of Co, Li, and Ni from Spent Li-Ion Batteries by the Inorganic and/or Organic Reducer Assisted Leaching Method

The battery powder (anodic and cathodic mass) manually separated from spent Li-ion batteries used in laptops was subjected to acidic reductive leaching to recover the Co, Li, and Ni contained in it. In the laboratory experiments, 1.5 M sulfuric acid was used as the leaching agent and the reducing agents were 30% H2O2 solution or/and glutaric acid. Glutaric acid is a potential new reducing agent in the leaching process of spent lithium-ion batteries (LIBs). The influence of the type of the used reducer on obtained recovery degrees of Co, Li, and Ni as well as the synergism of the two tested reducing compounds were analyzed. As a result, it was determined that it is possible to efficiently hydrometallurgically separate Co, Li, and Ni from battery powder into solutions. The highest recovery degrees of the investigated metals (Co: 87.85%; Li: 99.91%; Ni: 91.46%) were obtained for samples where two reducers, perhydrol and glutaric acid, were added, thus confirming the assumed synergic action of H2O2 and C5H8O4 in a given reaction environment.

Environmental impact of spent lithium ion batteries and green recycling perspectives by organic acids - A review

The huge usage of rechargeable batteries in electronics has added to a recurrent problem worldwide in generating tonnage of spent lithium-ion batteries (LIBs). The inadequacy of the resources of the depleting critical metals has also been described in vogue. The environmental assessment of the life cycle of the LIBs has been elucidated vis-a-vis the effects of raw material supply, transportation, and recycling. Based on the available work for recycling technologies, this review also attempts to elicit the various methods practiced in discharging/dismantling, classification, and separation of components followed by metal recovery. The authors have reviewed the major developments in the area of recycling of cathode material by using various acids for extraction of metals from spent LIBs, compared the merits and demerits of acids used and presented a comprehensive outlook to the processes formulated vis-à-vis imperative need for using green techniques. The necessity for benign recycling methods is stressed upon to alleviate the need for high temperature and oxidative acid leaching conditions. The various green lixiviants (organic acids) attempted to extract metals from spent LIBs have been discussed in detail with respect to the mechanism, efficacies as well as the various factors (selectivity, cost, etc.) that govern the use of organic acids in battery recycling. It was ascertained that the GHG emissions to extract Co using organic acids stand 1/8 of that using an inorganic acid leaching process. Efforts need to be envisaged in separating the leached metals from these lixiviants ensuring economics and environmental benefits.

A new model of trajectory in eddy current separation for recovering spent lithium iron phosphate batteries

Eddy current separation (ECS) is an environment-friendly technology for separating nonferrous metallic particles whose size was from 2 mm to 10 mm. No wastes are generated in ECS. ECS quality of nonferrous metals from solid wastes is rather low in the production practice of spent lithium iron phosphate (LFP) batteries recovering. Repeating separation even manual sorting is required in the production. The traditional method of falling point prediction based on eddy current mechanics uses equivalent acceleration to replace separation motion curves. These curves have low precision and are unsuitable for predicting the motion trajectory of small particle size of sorted materials. In this work, eddy current separation of positive and negative plates in a crushed product of spent lithium iron phosphate battery is used as an example to establish the force and kinematics models of different materials in the eddy current separation. An iterative method, rather than average speed method, is used to improve the accuracy of the model. Displacement interval replaces disengagement angle as a separating index to improve the model's intuitiveness and practical guidance. In the range of 2-20 mm, test results are consistent with simulation results. The copper and aluminium foils at a magnetic roller speed of 800r/min can be separated to a maximum particle size ratio of 1.72, and the maximum particle size ratio of copper and positive electrode sheets can be large. This paper provided an environmental-friendly and effective technology for separating nonferrous metals from crushed spent LFP batteries.

Eddy current separation for recovering aluminium and lithium-iron phosphate components of spent lithium-iron phosphate batteries

With the rapid development of the electric vehicle market since 2012, lithium-iron phosphate (LFP) batteries face retirement intensively. Numerous LFP batteries have been generated given their short service life. Thus, recycling spent LFP batteries is crucial. However, published information on the recovery technology of spent LFP batteries is minimal. Traditional separators and separation theories of recovering technologies were unsuitable for guiding the separation process of recovering metals from spent LFP batteries. The separation rate of the current method for recovering spent LFP batteries was rather low. Furthermore, some wastewater was produced. In this study, spent LFP batteries were dismantled into individual parts of aluminium shells, cathode slices, polymer diaphragms and anode slices. The anode pieces were scraped to separate copper foil and anode powder. The cathode pieces were thermally treated to reduce adhesion between the cathode powder and the aluminium foil. The dissociation rate of the cathode slices reached 100% after crushing when the temperature and time reached 300℃ and 120 min, respectively. Eddy current separation was performed to separate nonferrous metals (aluminium) from aluminium and LFP mixture. The optimized operation parameters for the eddy current separation were feeding speed of 1 m/s and magnetic field rotation speed of 4 m/s. The separation rate of the eddy current separation reached 100%. Mass balance of the recovered materials was conducted. Results showed that the recovery rate of spent LFP can reach 92.52%. This study established a green and full material recovery process for spent LFP batteries.

Maleic, glycolic and acetoacetic acids-leaching for recovery of valuable metals from spent lithium-ion batteries: leaching parameters, thermodynamics and kinetics

Environmentally friendly acid-leaching processes with three organic acids (maleic, glycolic and acetoacetic) were developed to recover valuable metals from the cathodic material of spent lithium-ion batteries (LiCoO₂). The leaching efficiencies of Li and Co by the maleic acid were 99.58% and 98.77%, respectively. The leaching efficiencies of Li and Co by the glycolic acid were 98.54% and 97.83%, while those by the acetoacetic acid were 98.62% and 97.99%, respectively. The optimal acid concentration for the maleic acid-, glycolic acid- and acetoacetic acid-leaching processes were 1, 2 and 1.5 mol l^-1, respectively, while their optimal H₂O₂ concentrations were 1.5, 2 and 1.5 vol%, respectively. The optimal solid/liquid ratio, temperature and reaction time for the leaching process of the three organic acids was the same (10 g l^-1, 70°C, 60 min). The thermodynamic formation energy of the leaching products and the Gibbs free energy of the leaching reactions were calculated, and the kinetic study showed that the leaching processes fit well with the shrinking-core model. Based on the comparison in the leaching parameters, the efficacy and availability of the three acids is as follows: maleic acid > acetoacetic acid > glycolic acid.

Combined mechanical process recycling technology for recovering copper and aluminium components of spent lithium-iron phosphate batteries

The recycling processes of spent lithium iron phosphate batteries comprise thermal, wet, and biological and mechanical treatments. Limited research has been conducted on the combined mechanical process recycling technology and such works are limited to the separation of metal and non-metal materials, which belongs to mechanical recovery. In this article the combined mechanical process recycling technology of spent lithium iron phosphate batteries and the separation of metals has been investigated. The spent lithium iron phosphate batteries monomer with the completely discharged electrolyte was subjected to perforation discharge. The shell was directly recycled and the inner core was directly separated into a positive electrode piece, dissepiment, and negative electrode piece. The dissociation rate of the positive and negative materials reached 100.0% after crushing when the temperature and time reached 300 °C and 120 min. The crushed products were collected and sequentially sieved after the low-temperature thermal treatment. Then, nonferrous metals (copper and aluminium) were separated from the crushed spent lithium iron phosphate batteries by eddy current separation with particle size -4 + 0.4. The optimised operation parameters of eddy current separation were fed at speeds of 40 r min^-1, and the rotation speed of the magnetic field was 800 r min^-1. The nonferrous metals of copper and aluminium were separated by the method of pneumatic separation. The optimal air speed was 0.34 m s^-1 for the particle-size -1.6 + 0.4 mm and 12.85-14.23 m s^-1 for the particle-size -4 + 1.6 mm. The present recycling process is eco-friendly and highly efficient and produces little waste.

A closed-loop process to recover Li and Co compounds and to resynthesize LiCoO2 from spent mobile phone batteries

In the last decades, the demand for lithium-ion batteries (LIBs) has been growing fast to attend the markets of electric and hybrid vehicles and of electric portable devices. As scarce metals like cobalt and lithium are employed in their manufacturing the recycling of spent LIBs is a strategic solution for the sustainability of these minerals and also the maintenance of the LIBs production. Therefore, efforts should be driven to produce low cost, environment-friendly and industrially scalable recycling processes. In this study, a closed-loop process with these characteristics was developed to recover cobalt and lithium compounds from LiCoO₂ cathodes of spent cell phone lithium-ion batteries. The process employs citric acid as green leaching agent to recover cobalt as CoC₂O₄.2H₂O and Co₃O₄ and lithium as Li₂CO₃. Lithium compound was recovered from a proposed new and original method based on simple chemical procedures as evaporation-calcination and water dissolution. The developed process also allows the resynthesis of LiCoO₂ as a stoichiometric, well crystallized and structurally ordered compound from the recovered Co and Li compounds, in a closed-loop recycling process. The obtained results indicate that the developed process has great potential to be scaled up to a recycling industrial plant of spent lithium-ion batteries.

A review on management of spent lithium ion batteries and strategy for resource recycling of all components from them

The wide use of lithium ion batteries (LIBs) has brought great numbers of discarded LIBs, which has become a common problem facing the world. In view of the deleterious effects of spent LIBs on the environment and the contained valuable materials that can be reused, much effort in many countries has been made to manage waste LIBs, and many technologies have been developed to recycle waste LIBs and eliminate environmental risks. As a review article, this paper introduces the situation of waste LIB management in some developed countries and in China, and reviews separation technologies of electrode components and refining technologies of LiCoO₂ and graphite. Based on the analysis of these recycling technologies and the structure and components characteristics of the whole LIB, this paper presents a recycling strategy for all components from obsolete LIBs, including discharge, dismantling, and classification, separation of electrode components and refining of LiCoO₂/graphite. This paper is intended to provide a valuable reference for the management, scientific research, and industrial implementation on spent LIBs recycling, to recycle all valuable components and reduce the environmental pollution, so as to realize the win-win situation of economic and environmental benefits.

Sustainable recovery of valuable metals from spent lithium-ion batteries using DL-malic acid: Leaching and kinetics aspect

An eco-friendly and benign process has been investigated for the dissolution of Li, Co, Ni, and Mn from the cathode materials of spent LiNi_1/3Co_1/3Mn_1/3O₂ batteries, using DL-malic acid as the leaching agent in this study. The leaching efficiencies of Li, Co, Ni, and Mn can reach about 98.9%, 94.3%, 95.1%, and 96.4%, respectively, under the leaching conditions of DL-malic acid concentration of 1.2 M, hydrogen peroxide content of 1.5 vol.%, solid-to-liquid ratio of 40 g l^-1, leaching temperature of 80°C, and leaching time of 30 min. In addition, the leaching kinetic was investigated based on the shrinking model and the results reveal that the leaching reaction is controlled by chemical reactions within 10 min with activation energies (Ea) of 21.3 kJ·mol^-1, 30.4 kJ·mol^-1, 27.9 kJ·mol^-1, and 26.2 kJ·mol^-1 for Li, Co, Ni, and Mn, respectively. Diffusion process becomes the controlled step with a prolonged leaching time from 15 to 30 min, and the activation energies (Ea) are 20.2 kJ·mol^-1, 28.9 kJ·mol^-1, 26.3 kJ·mol^-1, and 25.0 kJ·mol^-1 for Li, Co, Ni, and Mn, respectively. This hydrometallurgical route was found to be effective and environmentally friendly for leaching metals from spent lithium batteries.

A combined process for cobalt recovering and cathode material regeneration from spent LiCoO2 batteries: Process optimization and kinetics aspects

A combined process has been developed for recovering cobalt and regenerating cathode material from leach liquor of spent LiCoO₂ batteries. Cobalt of 98% can be selectively separated from leach liquor using ammonium oxalate of 1.15 (mole ratio) at pH of 2.0, 55 °C, and 40 min. Kinetics analysis indicates that precipitation of cobalt is controlled by a combination of surface chemical reaction and diffusion. The E_a value of precipitation is 19.68 kJ/mol obtained from the second-order model of (1 - a)^-1 = k't + c. Based on the TG/DSC curves of oxidation of cobalt oxalate, it is found that formation of Co₃O₄ oxidized from cobalt oxalate is in according with the model of randomly nucleating followed by nucleus growth. The E_a value is 84.93 kJ/mol that is provided by the suitable model of g(α) = [-ln(1 - α)]^1/3. Then, lithium is recovered from the filtrate as Li₂CO₃ with the purity of 99.5% by precipitation method. Finally, new cathode material with a good electrochemical performance is regenerated using obtained Co₃O₄ and lithium carbonate through solid phase method.

Process for recycling mixed-cathode materials from spent lithium-ion batteries and kinetics of leaching

A "grave-to-cradle" process for the recycling of spent mixed-cathode materials (LiCoO₂, LiCo_1/3Ni_1/3Mn_1/3O₂, and LiMn₂O₄) has been proposed. The process comprises an acid leaching followed by the resynthesis of a cathode material from the resulting leachate. Spent cathode materials were leached in citric acid (C₆H₈O₇) and hydrogen peroxide (H₂O₂). Optimal leaching conditions were obtained at a leaching temperature of 90 °C, a H₂O₂ concentration of 1.5 vol%, a leaching time of 60 min, a pulp density of 20 g L^-1, and a citric acid concentration of 0.5 M. The leaching efficiencies of Li, Co, Ni, and Mn exceeded 95%. The leachate was used to resynthesize new LiCo_1/3Ni_1/3Mn_1/3O₂ material by using a sol-gel method. A comparison of the electrochemical properties of the resynthesized material (NCM-spent) with that synthesized directly from original chemicals (NCM-syn) indicated that the initial discharge capacity of NCM-spent at 0.2 C was 152.8 mA h g^-1, which was higher than the 149.8 mA h g^-1 of NCM-syn. After 160 cycles, the discharge capacities of the NCM-spent and NCM-syn were 140.7 mA h g^-1 and 121.2 mA h g^-1, respectively. After discharge at 1 C for 300 cycles, the NCM-spent material remained a higher capacity of 113.2 mA h g^-1 than the NCM-syn (78.4 mA h g^-1). The better performance of the NCM-spent resulted from trace Al doping. A new formulation based on the shrinking-core model was proposed to explain the kinetics of the leaching process. The activation energies of the Li, Co, Ni, and Mn leaching were calculated to be 66.86, 86.57, 49.46, and 45.23 kJ mol^-1, respectively, which indicates that the leaching was a chemical reaction-controlled process.

Hydrometallurgical recycling of lithium-ion batteries by reductive leaching with sodium metabisulphite

The hydrometallurgical extraction of metals from spent lithium-ion batteries (LIBs) was investigated. LIBs were first dismantled and a fraction rich in the active material was obtained by physical separation, containing 95% of the initial electrode, 2% of the initial steel and 22% of plastic materials. Several reducers were tested to improve metals dissolution in the leaching step using sulphuric acid. Sodium metabisulphite led to the best results and was studied in more detail. The best concentration of Na₂S₂O₅ was 0.1 M. The metals dissolution increased with acid concentration, however, concentrations higher than 1.25 M are unnecessary. Best results were reached using a stirring speed of 400 min^-1. The metals leaching efficiency from the active material (Li, Mn, Ni, Co) increased with the temperature and was above 80% for temperatures higher than 60 °C. The dissolution of metals also rose with the increase in the liquid/solid ratio (L/S), however, extractions above 85% can be reached at L/S as lower as 4.5 L/kg, which is favourable for further purification and recovery operations. About 90% of metals extraction can be achieved after only 0.5 h of leaching. Sodium metabisulphite can be an alternative reducer to increase the leaching of Li, Mn, Co, and Ni from spent LIBs.