Recovery of Graphite and Cathode Active Materials from Spent Lithium-Ion Batteries by Applying Two Pretreatment Methods and Flotation Combined with a Rapid Analysis Technique

A study on recovery strategies of graphite from mixed lithium-ion battery chemistries using froth flotation

The growing electric vehicle industry has increased the demand for raw materials used in lithium-ion batteries (LIBs), raising concerns about material availability. Froth flotation has gained attention as a LIB recycling method, allowing the recovery of low value materials while preserving the chemical integrity of electrode materials. Furthermore, as new battery chemistries such as lithium titanate (LTO) are introduced into the market, strategies to treat mixed battery streams are needed. In this work, laboratory-scale flotation separation experiments were conducted on two model black mass samples: i) a mixture containing a single cathode (i.e., NMC811) and two anode species (i.e., LTO and graphite), simulating a mixed feedstock prior to hydrometallurgical treatment; and ii) a graphite-TiO2 mixture to reflect the expected products after leaching. The results indicate that graphite can be recovered with > 98 % grade from NMC811-LTO-graphite mixtures. Additionally, it was found that flotation kinetics are dependent on the electrode particle species present in the suspension. In contrast, the flotation of graphite from TiO2 resulted in a low grade product (<96 %) attributed to the significant entrainment of ultrafine TiO2 particles. These results suggest that flotation of graphite should be preferably carried out before hydrometallurgical treatment of black mass.

Lithium aluminate flotation by pH- and light-switchable collectors based on the natural product punicine

Derivatives of the natural product punicine [1-(2',5'-dihydroxyphenyl)pyridinium chloride] were developed as switchable collectors for the flotation of lithium-containing engineered artifical minerals (EnAMs). These EnAMs are e.g. formed by pyrometallurgical processing of end-of-life lithium-ion batteries. Depending on the pH value and the lighting conditions, punicines exist in water as cations, two different electrostatically neutral mesomeric betaines, anionic tripoles, radical cations or radical anions. The radical species form by photochemically induced disproportionation reactions. We prepared punicine derivatives introducing alkyl chains in the pyridinium moiety (4-methyl, 4-ethyl, 4-octyl and 4-undecanyl) to install hydrophobic groups and examined the recovery rates of the flotation of lithium aluminate (LiAlO2). We varied the lighting conditions (darkness, daylight, LED irradiation at λ = 390-400 nm) and the pH value, the collector's and frother's concentration, and the flotation time. With our collectors, recovery rates of lithium aluminate up to 90% were accomplished when the flotation was conducted in Hallimond tubes exposed to daylight at pH 11 in water.

A simple methodology for the quantification of graphite in end-of-life lithium-ion batteries using thermogravimetric analysis

A new method based on thermogravimetric analysis was developed to measure the graphite content in battery material mixture. This approach exploits the thermochemical reduction of cathodic Li-transition metal oxides with anodic graphite at elevated temperatures under an inert atmosphere. Using known composition artificial mixtures, a linear correlation between cathode mass loss and sample graphite content was observed. The method was validated using industrial black mass samples and characterized traditionally to estimate and rationalize potential error sources. Thermal degradation profiles of industrial battery waste reflected those in the artificial system, demonstrating its applicability. This work also demonstrates that thermogravimetric degradation profiles can distinguish between a cathode consisting of single or multiple Li-metal oxides. Although accuracy depends on active component mixture content and impurities, it is demonstrated that the method is useful for a fast graphite content estimation. Unlike other graphite characterization techniques, the method proposed is simple and inexpensive.

The Recycling of Spent Lithium-Ion Batteries: Crucial Flotation for the Separation of Cathode and Anode Materials

The recycling of spent lithium-ion batteries (LIBs) has attracted great attention, mainly because of its significant impact on resource recycling and environmental protection. Currently, the processes involved in recovering valuable metals from spent LIBs have shown remarkable progress, but little attention has been paid to the effective separation of spent cathode and anode materials. Significantly, it not only can reduce the difficulty in the subsequent processing of spent cathode materials, but also contribute to the recovery of graphite. Considering the difference in their chemical properties on the surface, flotation is an effective method to separate materials, owing to its low-cost and eco-friendly characteristics. In this paper, the chemical principles of flotation separation for spent cathodes and materials from spent LIBs is summarized first. Then, the research progress in flotation separation of various spent cathode materials (LiCoO₂, LiNi_xCo_yMn_zO₂, and LiFePO₄) and graphite is summarized. Given this, the work is expected to offer the significant reviews and insights about the flotation separation for high-value recycling of spent LIBs.