EV Battery Metal Extraction and Recovery Processes

The use of Li-ion batteries is drastically increasing, especially due to the growing sales electric vehicles. Simultaneously, there a shift towards exchanging traditional Co- and Ni-rich electrode materials with more sustainable alternatives such as LiFePO4. This transition challenges conventional recycling practices, which typically rely on shredding into substance known black mass, subsequently processed via hydrometallurgical or pyrometallurgical methods extract valuable elements. These routes may not be economically viable for future chemistries lower contents high-value metal. Hence, new processing allowing, e.g., physical separation direct recycling, are direly needed. Such developments require that mass thoroughly understood. In this study, we characterize commercially produced Graphite/LFP sample from real battery waste using suite analytical techniques. Our findings reveal detailed chemical, morphological, structural insights show components in have different micro-size profiles, enable simple size separation. Unfortunately, our analysis also reveals employed leads formation... Read More

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A sustainable process for recycling materials from used lithium-ion batteries and other energy storage devices. The process involves washing, discharging, crushing, separating, baking, dissolving, filtering, heating, acid leaching, mixing, and drying steps to extract and recover battery-grade metals and non-metals like cobalt, nickel, lithium, copper, aluminum, graphite, sulfates, carbonates, and lithium carbonate. It aims to recover high-purity metal salts with minimal energy and water, while reducing emissions compared to smelting.

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Apparatus for efficiently recycling waste lithium-ion battery components like electrolyte, slurry and positive electrode material. The recycling system uses a turntable with fixed assemblies to suction, shake and drop out the battery contents. The slurry and electrolyte are centrifuged to separate and recycle. The solid positive electrode material is calcined, crushed and acid leached. This allows efficient and harmless recycling of all battery components without volatile gas release. The system has a simple flow, high efficiency and prevents environmental pollution compared to existing battery recycling methods.

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A low-cost, efficient method to recycle lithium iron phosphate (LFP) batteries and produce high-purity LFP precursor material for reuse in new batteries. The recycling process involves steps like acid leaching, copper electrolysis, iron oxidation, iron phosphate precipitation, and lithium carbonate precipitation. It separates and removes impurities like copper and aluminum from the LFP precursor, reducing impurity content compared to other methods.

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As demand for lithiumion batteries increases, the supply of materials is increasingly constrained by their geographical concentration. This has spurred significant research into recycling spent to enhance resource circulation. Currently, commercially applied methods (such as pyrometallurgy and hydrometallurgy) face environmental economic challenges, including waste acid gas generation, hightemperature heat treatment, operational complexity. A promising alternative carbothermic reduction process, which operates at lower temperatures, minimizing costs emissions. However, this method still requires large quantities external reducing agents. Therefore, study aims introduce a simplified direct (SDCR) process. The SDCR process leveraged carbon conductive organic binders within electrode Additionally, high compaction state created conducive environment gases, promoting efficient material recovery. approach reduces reliance on agents streamlines reupcycling making it viable.

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Abstract: The rapid proliferation of electric vehicles (EVs) has significantly contributed to reducing greenhouse gas emissions and advancing sustainable transportation systems. Central the functionality these EVs are lithium-ion batteries (LiFePO4), known for their high energy density long lifespan. However, as EV market continues expand, growing issue battery waste management presents considerable environmental economic challenges. This paper provides a comprehensive overview three main types utilized in vehicles, namely, Lithium Iron Phosphate (LFP), Nickel Manganese Cobalt (NMC) aluminum (NCA) batteries. It examines challenges opportunities recycling disposal within broader context ongoing crisis. As demand clean technologies intensifies, becomes crucial ensure long-term viability renewable systems addressing resource scarcity. review explores complexities involved disposal. discusses four prominent methods that available practice 2024. advantages disadvantages each carefully evaluated discussed thoroughly paper. findings underscore urgent need collaborative efforts among policym... Read More

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Battery recycling process that safely discharges batteries before crushing to prevent explosions. The method involves cooling the batteries in a gaseous environment to around -60°C to 0°C for discharge, then crushing at temperatures around -10°C to 10°C. This prevents short circuits and explosions during crushing by safely discharging the residual energy. The cooling is done in a chamber with controlled temperature sensing to ensure complete discharge before crushing.

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Recycling the positive electrode materials of spent Li-ion batteries is critical for environmental sustainability and resource security. To facilitate attainment goal, this study presents a novel approach recovering valuable metals from lithium-ion (LIBs) in an H-shaped cell containing aqueous NaCl electrolyte. The process employs hydrochloric acid that could be derived chlorine cycle as leaching agent. electrolytic device engineered to generate high pH gradient, thereby enhancing metal elements eliminating requirement external or base addition. This green recycling adheres principles circular economy provides environmentally friendly solution sustainable battery material recycling.

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Cathode active material is the most valuable component of spent lithiumion batteries (LIBs), accounting for approximately 30% their overall value. Direct recycling cathode materials involves recovering, regenerating, and reusing them without breaking down chemical structure. This approach maximizes added value compound reduces manufacturing costs by avoiding need virgin production. However, one key challenge in scaling direct from lab to industry requirement highly purified materials, contrasting with low purity black mass generated battery shredding. No efficient separation process currently exists isolate different lithiumnickelmanganesecobalt oxides (NMCs) each other. Thus, technologies that can operate mixtures multiple NMC stoichiometries will be bestsuited industrial adoption. study explores into 622 using a "reciprocal ternary molten salts (RTMS)" system. Ionothermal relithiation upcycling within RTMS system successfully restore layered structure, lithium content, electrochemical performance degraded NMCs, yielding results comparable pristine (PNMC 622).

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A closed loop process for selective recovery of lithium from recycled lithium-ion battery cathode materials. The process involves leaching lithium using concentrated formic acid, distilling to separate lithium formate and trace impurities, sintering to convert lithium formate to lithium carbonate, washing to dissolve lithium carbonate and leave impurity carbonates, and precipitating lithium carbonate in acetone. This allows >99% lithium recovery with >99% purity from recycled batteries. The formic acid can be reused and impurities like transition metal carbonates remain in the solid residue.

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Accumulating used lithium-ion battery cathodes and associated environmental concerns necessitate efficient recycling strategies. Biohydrometallurgical processes often face challenges at high pulp densities due to microbial inhibition substrate limitations, particularly sulfur availability, which is crucial for bacterial acidic agent production. This study introduces a breakthrough spent-medium bioleaching approach optimized high-pulp-density conditions. We systematically addressed key challenges, including inhibition, sulfuric acid optimization, its impact on critical metal dissolution. Using response surface methodology, we dosage, inoculum size, initial pH enhance production by Acidithiobacillus thiooxidans, achieving sulfate concentration of 40.3 g/l pH 1.87. Metal removal efficiency was assessed 10-50 g/l, demonstrating extraction rates Li (92%), Ni (88%), Co (78%) 50 after 7 days. Comparative analysis with chemical leaching confirmed the effectiveness this green strategy. Furthermore, kinetic using Avrami equation shrinking core model revealed that both models yield comparable... Read More

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Targeted recycling of waste lithium batteries using pyrolysis and CO gas to separate valuable metals like aluminum, cobalt and lithium. The method involves pyrolyzing the battery cathode strips in a CO atmosphere to agglomerate cobalt nanoparticles into larger millimeter-sized particles against the CO concentration gradient. This prevents alloying with aluminum and allows separation by magnetic separation. The aluminum foil collector from the original battery acts as a reducing agent for the aluminothermic reaction. The CO gas complexes nascent cobalt monomers but doesn't reduce metals like cobalt. The aluminum robs oxygen from metal oxides preferentially due to its lower oxygen partial pressure demand compared to CO.

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A method for preparing high-purity lithium sulfide with high yield using a reactor configuration and gas injection technique to efficiently convert solid sulfur and lithium sources into lithium sulfide. The reactor has sequential layers of solid sulfur and lithium source. A gas is injected into the reactor in a single direction to contact the layers and react them. This sequential gas flow enables high-purity lithium sulfide formation under mild conditions. The lithium source can be recovered from waste lithium battery cathodes. The lithium sulfide is then separated from the product by dissolution and solvent evaporation.

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Abstract Recycling endoflife lithiumion batteries (LIBs) to recover highvalue cathode materials such as LiNi x Mn y Co z O 2 (NMC) is driven by economical, geopolitical, and sustainability needs. There has been recent interest in direct recycling methods improve efficiency recovery of materials, including ionothermal, hydothermal, solidstate, or redox mediator methods. In conjunction with process development, detailed structural characterization necessary order understand the mechanisms efficacy steps. Solidstate nuclear magnetic resonance (NMR) spectroscopy a unique tool that can probe Li coordination, bulk surface environments, transition metal ordering recycled upcycled NMC cathodes. Here, 6,7 Li, 1 H, 19 F NMR compositional changes well impurities may form during each step utilized. During relithiation, reinsertion into lattice observed. upcycling, where goal increase Ni content NMC, incorporation Nirich phases environment Surface formed processing were also identified. These studies provide valuable information for optimizing processes reach targeted composi... Read More

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With the accelerated depletion of non-renewable resources and increased demand for lithium batteries, green recycling has become a key issue nowadays. In this study, effects mass ratio potassium persulfate to active material battery cathode material, roasting temperature, time, liquid-solid leaching time on rate lithium, cobalt, nickel manganese were investigated. For lithium-cobalt oxide materials, optimal conditions KSO LiCoO 2:3, temperature 700 C 60 min, 98.51% selective 99.86%. ternary NCM523, 1:2 ratio, reached 98.97%. The method positive corporate environmental impact by reducing need hazardous chemicals, lowering waste operating costs, avoiding harmful emissions. It is scalable cost-effective meets needs industry environmentally friendly resource recovery. K2S2Oroasting-water process proposed in study effectively overcomes problems acid pollution traditional recovery process, provides sustainable solution efficient batteries future.

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This article investigates decision-making strategies for power battery recycling and cascading utilization within the context of rapidly advancing blockchain technology, aiming to enhance sustainability efficiency energy storage systems. A closed-loop supply chain model is proposed, integrating key stakeholders such as manufacturers, OEM (original equipment manufacturer) vehicle third-party recyclers, tiered users, consumers. The study focuses on critical factors including competition among channels, level blockchain-enabled traceability, rate retired batteries. By analyzing four hybrid modes, research identifies optimal evaluates their economic environmental impacts. findings provide a theoretical foundation practical insights improving recycling, contributing development cleaner more efficient

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This study explores the use of a deep eutectic solvent (DES) composed choline chloride and pyrogallol (1:1 molar ratio) for recovery lithium, cobalt, nickel from spent lithium-ion battery cathodes based on LiNi0.33Co0.33Mn0.33O2 (NMC111). The DES exhibits moderate viscosity, intrinsic redox activity, strong complexation ability, enabling efficient metal dissolution under mild conditions. effects both temperature (5080 C) time (up to 12 h) leaching efficiency were systematically investigated. Optimal parameters80 C, 8 h, liquid-to-solid ratio 50yielded extraction efficiencies 92% Li, 85% Co, 88% Ni. Kinetic modeling indicated pseudo-first-order behavior with activation energies 26.6, 22.1, 25.2 kJ/mol Ni, respectively. Mechanistic analysis confirmed dual role as reducing agent (facilitating Co3+ Co2+ conversion) chelating ligand.

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Recovering lithium from lithium-ion battery scrap using a three-step process involving carbon dioxide water leaching, ion exchange resin purification, and thermal decomposition to produce high-purity lithium carbonate. The process involves roasting the battery scrap powder, grinding, carbon dioxide leaching to form lithium bicarbonate, ion exchange resin purification to remove impurities, and thermal decomposition to convert the lithium bicarbonate into lithium carbonate. This allows selective removal of impurities without additional chemicals and produces lithium carbonate with lower sodium and sulfur compared to conventional methods.

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A sustainable and cost-effective method to prepare sodium iron fluorophosphate cathode material for sodium-ion batteries using waste lithium iron phosphate from scrapped lithium-ion batteries. The method involves converting waste lithium iron phosphate into sodium iron fluorophosphate by reacting it with aluminum and sodium hydroxide, followed by calcination to remove lithium and aluminum. The calcined material is then carbon-coated. This allows recycling of lithium iron phosphate waste while leveraging the abundant sodium resource for sodium-ion batteries.

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<title>Abstract</title> Nowadays, the recycling of valuable metals from spent lithium-ion batteries (LIB) using hydrometallurgical processes is on rise. Therefore, safer leaching media for dissolution and environmentally friendly chemicals are essential. In this research, a feasibility study recovery metals, including lithium, cobalt, manganese, nickel, cathode LIB in acidic conditions pomegranate peel (PP) as green reductant was evaluated. To optimize process, effects various parameters, such CH₃COOH concentration, temperature, time, PP/LIB, were investigated response surface methodology (RSM) experimental design. Based ANOVA, linear models obtained Co, Mn, Li recovery, except Ni model. According to results, temperature identified most crucial factor Ni, Li, due facile hydrolysis PP at elevated temperatures. optimization results cathodes presence PP, predicted values optimum point 320 min, 5.5 M 92C PP/LIB 3.5 g/g 83.3, 85.9, 84.9, 91.2%, respectively, which showed good agreement with calculated recovery. FTIR characterization samples absence indicated that glucose mole... Read More

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