Antisolvent Precipitation for Metal Recovery from Citric Acid Solution in Recycling of NMC Cathode Materials

A comprehensive review of emerging technologies for recycling spent lithium-ion batteries

Along with the increasing demand for lithium-ion batteries (LIB), the need for recycling major components such as graphite and different critical materials contained in LIB is also reaching a peak in the research community. Several authors review the different LIB recycling methodologies, including pyro- and hydrometallurgy processes. However, the characteristics, main stages, and achievements of LIB emerging recycling are still missing. This study reviews the diverse emerging approaches for recycling critical materials from spent LIB in the last five years. A classification for emerging recycling technologies is provided, including terms like development stage and eco-friendly status. The main stages of recycling LIB are opening, phase separation, and materials recovery. Among the emerging proposals with the highest industrialization potential are direct recycling techniques due to low costs and simple procedures. Concerning phase separation, froth flotation and ultrasound-assisted methods are discussed. The former divides black mass into pure anodic and cathodic materials, while ultrasonication is employed to physically detach active materials from foils or enhance binder degradation. As to materials recovery, several recent approaches show high recovery efficiency for different elements, mainly in leaching. The use of new organic acids, deep eutectic acids, and some salts are worth noting as leaching agents due to their low environmental impact. In addition, leaching methods assisted by ultrasound and microwave irradiation increase valuable metal recovery, reducing time consumption and the number of leaching reactants. As a part of the hydrometallurgy process, metallic ion purification is performed by solvent extraction and ion exchange, while selective precipitation can be achieved by specific chemical agents or electrochemical processes.

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

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

A comprehensive review on the ultrasound-enhanced leaching recovery of valuable metals: Applications, mechanisms and prospects

In recent two decades, ultrasound has been broadly applied to the hydrometallurgical leaching process to recover valuable metals within raw materials, aiming to solve the shortcomings of the conventional leaching process, including relatively low leaching recovery, long leaching duration, high reagent usage, high energy consumption and so on. The present work focuses on a comprehensive overview of the ultrasound-enhanced leaching of various metals, such as common nonferrous and ferrous metals, rare metals, rare earth elements, and precious metals, from raw metal ores and secondary resources. Moreover, the enhanced leaching mechanisms by ultrasound are discussed in detail and summarized based on the improvement of leaching kinetics, enhancement of the mass transfer and diffusion of lixiviants, and promotion of the oxidative conversion of metals from insoluble to soluble states. Lastly, the challenges and outlooks of future research on the leaching recovery for valuable metals with the assistance of ultrasound irradiation are proposed.

Kinetics study and recycling strategies in different stages of full-component pyrolysis of spent LiNixCoyMnzO2 lithium-ion batteries

Full-component pyrolysis has been proven to be a prospective method for the disposal of organic matters and the cathode material reduction of spent LiNi_xCo_yMn_zO₂ (NCM) lithium-ion batteries (LIBs). However, the kinetics of the full-component pyrolysis of spent NCM LIBs is still unclear. This work represents the first attempt to study the kinetics of different stages of full-component pyrolysis of NCM LIBs based on isoconversional method to guide the recycling of spent LIBs. Pyrolysis process was divided into four stages in accordance to the main weight loss temperature ranges and the classical Kissinger-Akahira-Sunose and Flynn-Wall-Ozawa kinetics models were employed to calculate the activation energy (E) in each stage. The main physicochemical reactions were clarified though in situ analysis, and the average E in the four stages was determined: (I) The volatilization of electrolytes occurred in the temperature range of 100-200 °C with the E of 98.6 kJ/mol. (II) The decomposition of organic matters and the preliminary reduction of cathode material transpired in the temperature range of 400-500 °C with the E of 227.2 kJ/mol. (III) The further reduction of NiO and CoO occurred from 650 to 800 °C with the E of 258.8 kJ/mol. (Ⅳ) The reduction of MnO took place from 850 to 1000 °C with the E of 334.9 kJ/mol. The recycling strategies based on full-component pyrolysis of spent NCM LIBs was accordingly proposed. During pyrolysis, the cathode material was gradually reduced and the pyrolytic products can be controlled through temperature regulation.