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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A method to extract valuable materials from used lithium-ion batteries in an efficient and environmentally friendly way. The method involves sorting, crushing, discharging, shredding, magnetic separation, and air separation steps to isolate and recover metals like lithium, cobalt, nickel, manganese, and carbon from the batteries. The steps are performed in stages to separate the battery components and extract the valuable metals. It aims to increase the extraction efficiency compared to direct smelting of whole batteries.

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The rapid growth of lithium iron phosphate (LiFePO4, LFP)-based lithium-ion batteries in energy storage raises urgent challenges for resource recovery and environmental protection. In this study, we propose a novel method selective extraction the resynthesis cathodes from spent LFP batteries, aiming to achieve an economically feasible efficient recycling process. process, leaching H2SO4-H2O2 system is employed rapidly selectively extract lithium, achieving efficiency 98.72% within just 10 min. Through exploration precipitation conditions lithium-containing solution, high-purity Li2CO3 successfully obtained. recovered FePO4 are then used resynthesize cathode materials through carbon-thermal reduction method. A preliminary economic analysis reveals that disposal cost approximately USD 2.63 per kilogram, while value regenerated reaches 4.46, highlighting advantages Furthermore, with acid-to-lithium molar ratio only 0.57-just slightly above stoichiometric 0.5-the process requires minimal acid usage, offering clear benefits. Overall, work presents green, efficient, viable strategy showcas... Read More

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Objective: The rapid growth of electric vehicle (EV) adoption has led to an unprecedented increase in lithium-ion battery (LIB) demand and end-of-life waste, underscoring the urgent need for effective recycling strategies. This review evaluates current progress EV explores future prospects. Design: Review based on PRISMA 2020. Data sources: Scientific publications indexed major databases such as Scopus, Web Science, ScienceDirect were searched relevant studies published between 2020 15 April 2025. Inclusion criteria: Studies included if they English 2025, focused batteries. Eligible specifically addressed (i) methods, technologies, material recovery processes batteries; (ii) impact recycled systems power generation grid stability; (iii) assessments materials used manufacturing, including efficiency recyclability. articles meta-analyses excluded ensure inclusion only original research data. extraction: independently screened extracted by two researchers analyzed rates, environmental impact, system-level energy contributions. One researcher all A second validated accuracy data then org... Read More

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Direct recycling of lithium-ion battery waste in a scalable and efficient manner to isolate, purify, and regenerate recoverable battery components. The recycling method involves steps like heat treatment to decompose binder, separation to isolate electrode material, surface treatment to remove coatings, relithiation to replenish active material, washing to remove impurities, chemical purification, and flotation to extract metals. It yields commercial-grade cathode and anode materials for reuse.

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With the shortage of fossil energy and global warming, traditional cars are gradually being replaced by new vehicles. The automobile industry has made great progress, in which lithium-ion battery is widely used. paper aims to discuss current status challenges application batteries field By combing analyzing relevant literature, it summarizes basic working principle, performance characteristics applications batteries, discusses detail technical bottlenecks encountered during their use vehicles, including density, charging speed, safety recycling. This proposes solutions these looks forward future development trend batteries. results indicate that although technology a broad prospect still necessary further improve its solve recycling problem order promote sustainable

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Nickel recovery method from complex raw materials using a hybrid pyrometallurgical-hydrometallurgical process. The method involves selectively leaching and recovering lithium from raw materials containing strong lithium bonds through thermal treatment. Then, roasting converts all the nickel-containing raw materials into a uniform phase. Leaching, neutralization, and purification processes follow to remove impurities. Finally, nickel is hydrogen reduced from the purified solution to recover nickel.

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A simple, low-cost, and environmentally-friendly method for recycling spent lithium-ion batteries by separating and recovering valuable components like cathode materials, anode materials, and metal foils. The method involves isolating a composite electrode, combining it with an aqueous buffer solution, delaminating the electrode material from the current collector, and recovering each separated component. The aqueous solution allows efficient separation without toxic solvents, avoiding complex multi-step processes. The recovered components can be reused to make new batteries.

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Lithium-ion battery (LIB) recycling aims to recover valuable materials present within end-of-life electrochemical cells. Industrial processes produce "black mass" from feedstock which desirable can be recollected. Spent cells first undergo mechanical shredding and sieving, organic components are removed by thermal treatment (pyrolysis) before hydrometallurgical processing is employed the constituent elements. Black mass may contain a range of reaction products, formed at high temperature during pyrolysis, due compositionally complex inhomogeneous nature feedstock. These however, have different elemental compositions, ratios, structures, making efficient recovery difficult. Here, we three distinct, industrially sourced black samples containing Li-(Ni x Mn y Co z )-O2 (x + = 1) positive electrodes varying composition. We employ suite structural compositional characterization techniques, including synchrotron X-ray neutron powder diffraction element specific analysis (X-ray photoelectron spectroscopy, fluorescence energy dispersive inductively coupled plasma optical emission spectroscop... Read More

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ABSTRACT The rapid emergence of lithiumion batteries (LIBs) to satisfy our ever increasing energy demands will result in a significant future waste problem at their end life. Lithium iron phosphate (LFP) as cathode material is now widely used LIBs with market share. It expected that there be volumes battery containing this the near future, and therefore it important develop methods for effectively repurposing LFP mitigate its impact on environment. In work we demonstrate from spent electrocatalysts oxygen evolution reaction (OER) which critical electrochemical water splitting production green hydrogen. Our study has shown recovered once immobilized onto Ni substrate reconstructs into mixed Fe/Ni oxide surface layer highly active OER. Promisingly, were cycled multiple times (up 100 cycles) showed excellent electrocatalytic performance low Tafel slope 58 mV dec 1 , overpotential values 250 310 reach 10 mA cm 2 respectively 24 h stability over 200 . This research provides potential motivation recycling companies isolate Li ion later use electrolysis technologies.

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Recovering manganese, cobalt, and nickel from lithium-ion battery waste streams in separate streams. The process involves separating manganese, then separating cobalt and nickel. Manganese separation involves oxidation to precipitate manganese dioxide, then filtration to remove it. Cobalt and nickel separation involves sulfuric acid, oxidant, pH adjustment, and filtration to form cobalt oxyhydroxide and nickel sulfate solutions. The cobalt solution is further purified and adjusted pH to precipitate cobalt hydroxide. The nickel solution can be concentrated and adjusted pH to precipitate nickel hydroxide.

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A blockchain-based system for managing digital battery passports that provides transparency and traceability for battery lifecycle data. The system involves a distribution module connecting to manufacturer modules to manage digital battery passports. A user accesses a passport using a code. The distribution module retrieves data from the manufacturer's module using the code, and provides it to the user. The module also detects passport tampering. This allows users to access battery data across manufacturers and track things like performance, sustainability, and recycling.

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Abstract Landfilling of endoflife lithiumsulfur (LiS) batteries results in the loss valuable materials, soil contamination from hazardous electrolytes, and risks explosions caused by reactive lithium metals. Recycling LiS is crucial for battery sustainability circularity. However, recycling cathodes imposes a challenge because sulfur removal cumbersome costly. This study demonstrates that sulfurcarbon composites recycled can be reused to capture CO 2 . Specifically, charge/discharge cycling expands lattices carbons, causing exfoliation enlarge surface areas enhance adsorption. The acid treatment inserts oxygenfunctional groups into composite, further promoting capture. findings unveil increases uptake efficiency highlighting costeffective strategy promising reuse pathway sulfurbased achieve deeper decarbonization.

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Recovering cobalt and nickel from acidic solutions obtained by dissolving lithium ion battery waste in acids to produce high purity metal salts for reuse in battery production. The recovery process involves two extraction steps using solvent extraction and stripping. In the first step, cobalt ions are extracted from the acidic solution and then stripped into a solution. This stripped solution is then subjected to a second extraction step to further extract cobalt ions. This two-stage extraction process allows efficient cobalt recovery while effectively removing impurities from the acidic solution.

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Recycling lithium-ion batteries in a simple, efficient, and environmentally friendly way that enables reuse of the valuable cathode materials. The recycling process involves leaching the spent battery materials to extract the desirable cathode elements like Co, Ni, and Mn. The extracted ions are then recombined in a controlled pH environment to form the same ratios of cathode materials as the original battery. This allows making new cathode material with the same chemistry and capacity as the recycled batteries. The recombination is done using a reducing agent to maintain the ions in the desired oxidation state for precipitation into dense spherical particles. This avoids the complex high-temperature separations used in conventional recycling.

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Process for independently recovering manganese, cobalt, and nickel from lithium-ion battery waste streams. The process involves separating and purifying these metals from the waste stream using steps like oxidation, acidification, solvent extraction, and filtration. Manganese is separated by oxidation to form solid manganese dioxide, which is removed. Nickel and cobalt are separated by oxidation and pH adjustment, followed by filtration. Lithium can also be recovered. The separated metals are further purified.

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The increasing demand for lithium-ion batteries (LIBs) and their limited lifespan emphasize the urgent need sustainable recycling strategies. This study investigates application of tetrabutylphosphonium-based ionic liquids (ILs) as alternative leaching agents recovering critical metals, Li(I), Co(II), Ni(II), Mn(II), from spent NMC cathode materials. Initial screening experiments evaluated efficiencies nine ILs revealing distinct metal dissolution behaviors. Three containing HSO4, EDTA2, DTPA3 anions exhibited highest performance were selected further optimization. Key parameters, including IL acid concentrations, temperature, time, solid-to-liquid ratio, systematically adjusted, achieving exceeding 90%. Among tested systems, [TBP][HSO4] enabled near-complete (~100%) even at room temperature. Furthermore, an aqueous biphasic system (ABS) was investigated utilizing in combination with ammonium sulfate, enabling complete extraction all metals into salt-rich phase while leaving metal-free potentially suitable reuse, indicating feasibility integrating a continuous, interconnecte... Read More

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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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