EV Battery Metal Extraction and Recovery Processes

Efficient and cost-effective method to extract cobalt and nickel from lithium-ion battery cathodes using acid leaching. The method involves leaching the electrode material with sulfuric acid, adding hydrogen peroxide to reduce the metal ions, and adjusting pH to recover cobalt and nickel. This allows selective extraction of cobalt and nickel without leaching other elements like iron or manganese. Antifoaming agents are added to prevent foaming during leaching. The leaching conditions are optimized to efficiently dissolve the electrode material without adding excessive acid.

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Enhancing physical and electrochemical properties of recycled lithium-ion battery anode material by coating it with pitch. The recycled graphite from spent batteries is mixed with pitch and heated to form a coated graphite. More pitch and the coated graphite are combined and heated again to further enhance the properties. This multi-stage pitch coating process improves surface characteristics of the recycled graphite compared to uncoated recycled graphite, making it comparable or better than virgin graphite.

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Closed-loop process for recovering valuable metals like lithium, cobalt, manganese, nickel, and copper from lithium battery waste. The process involves leaching the metals from the battery material, removing them in steps like electroplating, precipitation, and solvent extraction, and then splitting the leach solution into hydroxide-rich and hydroxide-depleted streams. The hydroxide-rich stream is used to continue removing metals, while the hydroxide-depleted stream is recycled to the leaching step. This closed loop allows high purity metal recovery without forming mixed hydroxides.

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Autonomous robotic system for disassembling batteries and assessing their health without human intervention. The system uses robotic agents with non-intrusive sensors to move around the battery pack and measure parameters like temperature, voltage, and resistance. It identifies cell locations based on pack data, generates motion trajectories for the robotic agents to move to cells, and executes the trajectories. This allows autonomous, non-intrusive health assessment and disassembly of batteries. The system also uses high-fidelity disassembly and testing on some batteries to determine patterns of failure. This data is used to generate parameters for low-fidelity assessment, like specific cell locations, for faster and more efficient disassembly and health assessment of large numbers of batteries.

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Recycling lithium-ion battery waste by mechanically comminuting the batteries with water to separate and recover valuable materials like graphite and metals. The batteries with low charge are comminuted with water to prevent overheating and explosions. The comminuted mixture is separated into graphite-enriched and depleted fractions using screens. The graphite-enriched fraction is further processed to extract graphite. The depleted fraction is dried and further comminuted to separate the remaining graphite. The aerosol from comminution is also collected and processed. The water used is constantly supplied and discharged to dissipate heat.

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Recycling lithium-ion battery waste to extract and reuse valuable materials while improving battery performance and safety. The recycling process involves removing aluminum impurities from the waste, modifying them, and then incorporating them back into the recycled electrode material. This prevents negative effects of aluminum impurities on battery performance and safety. The aluminum impurities are removed via preprocessing steps like sieving, cyclones, air separation, elutriation, or dissolution. The removed aluminum is then modified into precursors like aluminum hydroxide that are applied to the recycled electrode material. This regenerated electrode material with modified aluminum impurities has improved performance and safety compared to using unmodified aluminum impurities from the waste.

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Direct recycling of lithium-ion batteries without dismantling the cells to extend battery life and reduce waste. The method involves removing the cells from an old battery, cleaning them, and re-lithiating them using lithium metal to restore capacity. The re-lithiated cells are then packaged in a new container with fresh electrolyte. This allows renewing the battery instead of fully recycling it, as the electrodes are reused. The cells are left intact to preserve their structure. The process involves removing electrolyte, re-lithiating, filling a new container, sealing, and adding new electrolyte.

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Preparing a two-dimensional sheet-like Li4SiO4 adsorbent using attapulgite clay and waste lithium batteries. The method involves carbothermal reduction of the batteries with biomass, followed by hydrothermal conversion of the attapulgite clay into the sheet-like Li4SiO4 adsorbent. This allows recycling lithium from the batteries using a low-cost clay source, while also creating an efficient adsorbent with improved CO2 capture capacity.

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A two-step smelting process to recover valuable metals like nickel (Ni) and cobalt (Co) from batteries and other sources. The process involves two smelting steps: (1) autogenous oxidizing smelting using the energy in the batteries, and (2) reducing smelting. This allows for autogenous smelting even with low aluminum (Al) and carbon (C) content in the batteries. The steps are: (1) oxidizing smelting to produce a Ni-Co alloy and a slag with Ni and Co levels below 1% each, (2) reducing smelting to further deplete the slag to below 0.1% Ni and Co, while maintaining a clean alloy. The slag is kept molten between steps to avoid solidification. The slag with low Ni and Co can be reused. The

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Recycling lithium-ion battery materials like nickel, cobalt, manganese and lithium from spent batteries in a sustainable way with reduced wastewater generation and lower CO2 footprint compared to existing methods. The process involves selectively precipitating and removing impurities like manganese, fluoride and phosphorous using lithium compounds like persulfate and hydroxide. This allows avoiding additional pH adjustments and reducing waste generation. The purified lithium solution is then further processed using chromatographic separation and concentration steps to recover high-purity lithium chemicals for battery production.

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Recycling lithium battery materials using a specialized apparatus that separates and extracts valuable metals from cathode materials. The process involves crushing, magnetic separation, winnowing, acid leaching, extraction, back-extraction, and saponification steps to recover elements like lithium, nickel, cobalt, manganese, and iron. It allows efficient recycling of metals from lithium batteries while minimizing waste and environmental impact.

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Abstract Recycling endoflife (EOL) lithiumion batteries (LIBs) is important to retain valuable resources from critical materials present in EOL battery waste. Direct recycling methods offer an opportunity recover intact cathode with minimal reprocessing. An step of the direct process relithiation which used restore lithium content materials. However, little has been done study how preprocessing steps such as washing or binder removal may affect process. Here, evolution fluorine byproducts left over during a lowtemperature chemical redox mediator tracked. A facile presented solution for mediating adverse effects surface contamination on performance. The structure, content, and electrochemical performance relithiated NMC 622 material that underwent prerelithiation remove shown match pristine 622. In this work, it showed part promising low energy method can be applied inherent impurities if proper processing are implemented.

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The recycling of lithium-ion batteries is picking up rather slowly, although recent rapid growth in consumption and increasing prevalence battery electric vehicles have increased the quantity recoverable material from past years production. Yet, diversity different product types i.e., chemistries life spans complicates recovery raw materials. At present, large-scale industrial employs (1) pyrometallurgy, with downstream hydrometallurgy for refined metals/salts; (2) hydrometallurgy, requiring upstream mechanical shredding cells and/or modules. Regulatory requirements, especially Europe, high industry concentration along value chain drive efforts forward. present study aims to quantify potential contribution 2nd lithium production on a global European scale 2050. overall output any given year depends interactions between several factors, including production, lifetime distributions, rates, all which are uncertain. simplest way propagate input uncertainties final results use Monte Carlo-type simulations. Calculations were done separately EVs portable batteries. supply sum contributions ... Read More

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This study investigates the optimization of an ammonia-based leaching process for recovery lithium and cobalt from spent LiCoO2 cathodes, coupled with energy-efficient ammonia stripping approach. Kinetic analysis revealed that both extraction follow pseudo-first-order kinetics, activation energies 76.54 kJ/mol 97.22 kJ/mol, respectively, indicating a chemically controlled process. Optimal conditions were established at 6 M NH3, 1.5 (NH4)2CO3, liquid-to-solid ratio 10:1, 70 C 5 h, achieving 82.5% 96.1% recovery. The was optimized energy efficiency, operations 9598 providing best balance between rapid NH3 removal consumption. At 98 C, demand reduced to ~282 sevenfold improvement over lower temperature operations. A stepwise separation strategy developed, involving selective precipitation pH 10.710.8, followed by precipitate 8.89.0. integrated approach offers promising alternative conventional acid-based recycling methods, combining high metal improved efficiency reagent recyclability.

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A method for recycling lithium batteries that provides a more efficient, less complex, and less costly process compared to existing methods. The method involves pyrolysis, gas-solid separation, gas combustion, and flue gas treatment to recover valuable metals like lithium, nickel, cobalt, and manganese from the battery components. The pyrolysis step involves heating the batteries to break down the materials. The gas-solid separation separates the pyrolysis products into a gas stream and a solid stream. The gas is combusted and the flue gas treated to meet emissions standards. The solid stream is further processed to extract the metals.

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Recycling lithium battery materials using chlorination. The process involves pyrolyzing the batteries to convert the contents into gases and solids. The gases are burned to generate heat. The solids, including metal sheets, powders, and carbon, are chlorinated at lower temperatures to extract the metals. This chlorination step is done in an oxygen-free environment. The chlorinated gases are then treated to remove pollutants and meet emissions standards. The chlorinated solids can be further processed to separate and recover the metals. The chlorination provides a more efficient and scalable way to extract valuable metals from recycled lithium batteries compared to traditional methods.

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A closed-loop and environmentally friendly method for recycling and regenerating retired nickel-cobalt-manganese (NCM) lithium-ion battery cathode materials without using strong acids or bases. The method uses citric acid as a leaching agent to extract metals like lithium, nickel, cobalt, and manganese from retired cathodes. It leaches at suitable conditions to achieve high metal recovery. The citric acid precursors are then mixed with lithium hydroxide and calcined to regenerate a new cathode with improved electrochemical performance compared to the original cathode. The citric acid leaching avoids secondary pollution compared to strong acids/bases and allows recycling of the filtrate.

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Recycling lithium battery metals using a wet processing method to extract valuable metals from cathode materials like lithium iron phosphate and ternary compounds without pre-separating the battery types. The process involves pyrolysis to convert the batteries to gases and solids, followed by gas cleaning and solid separation. The solids are treated with water to extract metal ions. This allows efficient separation and recovery of metals like lithium, nickel, manganese, and cobalt from the battery waste.

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Recycling method for lithium-ion batteries that improves efficiency and allows better extraction of valuable metals. The method involves two steps: (1) Li precipitation on the negative electrode by pulsed charging/discharging at low temperature, then (2) breaking down the positive electrode active material by charging/discharging in a low potential range. This miniaturizes the positive electrode material for easier separation and recovery of constituent metals during subsequent processing.

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Abstract The largescale production and EndofLife (EoL) of lithiumion batteries (LIBs) call for recycling with economic environmental efficiency. However, existing hydrometallurgical strategies typically consume huge amounts corrosive leachate without reusability, especially materials multiple types metallic elements. Herein, the successful realization reusability Rosa roxburghii type biomass is reported during wasted LI cathode. key to realizing relies on coprecipitation transition metal elements based coordination chemistry, which different from conventional method where alkali necessary neutralize precipitating It demonstrated that complete leaching NCM cathode at room temperature (25 C) 1 h, an activation energy E a = 70.30 kJ mol 1 . Highly efficient recovery achieved by using anhydrous oxalic acid (OA) (with efficiencies 97.21%, 98.78%, 96.55%, Ni, Co, Mn, respectively) neutralizing leachate, thus enabling reusability. structure electrochemical properties regenerated (RNCM111) are comparable those commercialized samples. This work expected provide general ... Read More

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