Influence of Cell Opening Methods on Electrolyte Removal during Processing in Lithium-Ion Battery Recycling

Review of lithium-ion batteries' supply-chain in Europe: Material flow analysis and environmental assessment

European legislation stated that electric vehicles' sale must increase to 35% of circulating vehicles by 2030, and concern is associated to the batteries' supply chain. This review aims at analysing the impacts (about material flows and CO2 eq emissions) of Lithium-Ion Batteries' (LIBs) recycling at full-scale in Europe in 2030 on the European LIBs' supply-chain. Literature review provided the recycling technologies' (e.g., pyro- and hydrometallurgy) efficiencies, and an inventory of existing LIBs' production and recycling plants in Europe. European production plants exhibit production capacity adequate for the expected 2030 needs. The key critical issues associated to recycling regard pre-treatments and the high costs and environmental impacts of metallurgical processes. Then, according to different LIBs' composition and market shares in 2020, and assuming a 10-year battery lifetime, the Material Flow Analysis (MFA) of the metals embodied in End of Life (EoL) LIBs forecasted in Europe in 2030 was modelled, and the related CO2 eq emissions calculated. In 2030 the European LIBs' recycling structure is expected to receive 664 t of Al, 530 t of Co, 1308 t of Cu, 219 t of Fe, 175 t of Li, 287 t of Mn and 486 t of Ni. Of these, 99% Al, 86% Co, 96% Cu, 88% Mn and 98% Ni will be potentially recovered by pyrometallurgy, and 71% Al, 92% Co, 92% Fe, 96% Li, 88 % Mn and 90% Ni by hydrometallurgy. However, even if the recycling efficiencies of the technologies applied at full-scale are high, the treatment capacity of European recycling plants could supply as recycled metals only 2%-wt of the materials required for European LIBs' production in 2030 (specifically 278 t of Al, 468 t of Co, 531 t of Cu, 114 t of Fe, 95 t of Li, 250 t of Mn and 428 t of Ni). Nevertheless, including recycled metals in the production of new LIBs could cut up 28% of CO2 eq emissions, compared to the use of virgin raw materials, and support the European batteries' value chain.

Fast and Efficient Evaluation of the Mass Composition of Shredded Electrodes from Lithium-Ion Batteries Using 2D Imaging

With the increasing number of electrical devices, especially electric vehicles, the need for efficient recycling processes of electric components is on the rise. Mechanical recycling of lithium-ion batteries includes the comminution of the electrodes and sorting the particle mixtures to achieve the highest possible purities of the individual material components (e.g., copper and aluminum). An important part of recycling is the quantitative determination of the yield and recovery rate, which is required to adapt the processes to different feed materials. Since this is usually done by sorting individual particles manually before determining the mass of each material, we developed a novel method for automating this evaluation process. The method is based on detecting the different material particles in images based on simple thresholding techniques and analyzing the correlation of the area of each material in the field of view to the mass in the previously prepared samples. This can then be applied to further samples to determine their mass composition. Using this automated method, the process is accelerated, the accuracy is improved compared to a human operator, and the cost of the evaluation process is reduced.