Recycling technologies of spent lithium-ion batteries and future directions:A review

Lithium-ion batteries(LIBs)are the most popular energy storage devices due to their high energy density,high operating voltage,and long cycle life.However,green and effective recycling methods are needed because LIBs contain heavy metals such as Co,Ni,and Mn and organic compounds inside,which seriously threaten human health and the environment.In this work,we review the current status of spent LIB recycling,discuss the traditional pyrometallurgical and hydrometallurgical recovery processes,and summarize the existing short-process recovery technologies such as salt-assisted roasting,flotation processes,and direct recycling.Finally,we analyze the problems and potential research prospects of the current recycling process,and point out that the multidisciplinary integration of recycling will become the mainstream technology for the development of spent LIBs.

Recovery of Li, Ni, Co and Mn from spent lithium-ion batteries assisted by organic acids: Process optimization and leaching mechanism

The proper recycling of spent lithium-ion batteries(LIBs)can promote the recovery and utilization of valuable resources,while also negative environmental effects resulting from the presence of toxic and hazardous substances.In this study,a new environmentally friendly hydro-metallurgical process was proposed for leaching lithium(Li),nickel(Ni),cobalt(Co),and manganese(Mn)from spent LIBs using sulfuric acid with citric acid as a reductant.The effects of the concentration of sulfuric acid,the leaching temperature,the leaching time,the solid-liquid ratio,and the reducing agent dosage on the leaching behavior of the above elements were investigated.Key parameters were optimized using response surface methodology(RSM)to maximize the recovery of metals from spent LIBs.The maxim-um recovery efficiencies of Li,Ni,Co,and Mn can reach 99.08%,98.76%,98.33%,and 97.63%.under the optimized conditions(the sulfuric acid concentration was 1.16 mol/L,the citric acid dosage was 15wt%,the solid-liquid ratio was 40 g/L,and the temperature was 83℃ for 120 min),respectively.It was found that in the collaborative leaching process of sulfuric acid and citric acid,the citric acid initially provided strong reducing CO_(2)^(-),and the transition metal ions in the high state underwent a reduction reaction to produce transition metal ions in the low state.Additionally,citric acid can also act as a proton donor and chelate with lower-priced transition metal ions,thus speeding up the dissolution process.

Selective leaching of lithium from spent lithium-ion batteries using sulfuric acid and oxalic acid

Traditional hydrometallurgical methods for recovering spent lithium-ion batteries(LIBs)involve acid leaching to simultaneously extract all valuable metals into the leachate.These methods usually are followed by a series of separation steps such as precipitation,extraction,and stripping to separate the individual valuable metals.In this study,we present a process for selectively leaching lithium through the synergistic effect of sulfuric and oxalic acids.Under optimal leaching conditions(leaching time of 1.5 h,leaching temperature of 70°C,liquid-solid ratio of 4 mL/g,oxalic acid ratio of 1.3,and sulfuric acid ratio of 1.3),the lithium leaching efficiency reached89.6%,and the leaching efficiencies of Ni,Co,and Mn were 12.8%,6.5%,and 21.7%.X-ray diffraction(XRD)and inductively coupled plasma optical emission spectrometer(ICP-OES)analyses showed that most of the Ni,Co,and Mn in the raw material remained as solid residue oxides and oxalates.This study offers a new approach to enriching the relevant theory for selectively recovering lithium from spent LIBs.

Selective lithium recovery and regeneration of ternary cathode from spent lithium-ion batteries:Mixed HCl-H_(2)SO_(4) leaching-spray pyrolysis approach

The recycling of spent lithium-ion batteries(LIBs) is crucial for environmental protection and resource sustainability.However,the economic recovery of spent LIBs remains challenging due to low Li recovery efficiency and the need for multiple separation operations.Here,we propose a process involving mixed HCl-H_(2)SO_(4) leaching-spray pyrolysis for recycling spent ternary LIBs,achieving both selective Li recovery and the preparation of a ternary oxide precursor.Specifically,the process transforms spent ternary cathode(LiNi_(x)Co_yMn_(2)O_(2),NCM) powder into Li_(2)SO_(4) solution and ternary oxide,which can be directly used for synthesizing battery-grade Li_(2)CO_(3) and NCM cathode,respectively.Notably,SO_(4)^(2-) selectively precipitates with Li^(+) to form thermostable Li_(2)SO_(4) during the spray pyrolysis,which substantially improves the Li recovery efficiency by inhibiting Li evaporation and intercalation.Besides,SO_(2) emissions are avoided by controlling the molar ratio of Li^(+)/SO_(4)^(2-)(≥2:1),The mechanism of the preferential formation of Li_(2)SO_(4) is interpreted from its reverse solubility variation with temperature.During the recycling of spent NCM811,92% of Li is selectively recovered,and the regenerated NCM811 exhibits excellent cycling stability with a capacity retention of 81.7% after 300 cycles at 1 C.This work offers a simple and robust process for the recycling of spent NCM cathodes.

A review of cathode and electrolyte recovery from spent lithium-ion batteries: Recent technologies, processes and policies

Recently,lithium-ion batteries(LIBs),due to their superior performance,have been vastly applied in electronic,auto,and other industries,resulting in the generation of an increasing amount of spent LIBs.What’s worse,LIBs contained potentially toxic substances,including heavy metals,toxic and flammable electrolyte containing LiBF_(4),LiClO_(4),and LiPF_(6).Conventional disposal of spent LIBs via landfill or incineration exerts tremendous pressure on the environment.It was necessary to adopt efficient,low-cost,and environmentally friendly approaches to valorizing spent LIBs,which could not only alleviate the shortage of rare resources by recycling valuable ele-ments such as Cu,Li,Mn,Ni,Co,and Al,but also eliminate the pollution of harmful components in batteries and realize the recycling and sustainable industry related to consumer electronics and electric vehicles(EVs).Given this,this paper summarized the recycling technologies of spent LIBs,including pyrometallurgy(melting reduction and roasting methods)and hydrometallurgy(leaching,precipitation,extraction,ion-exchange,elec-trochemical,sol-gel methods),and electrolyte recycling(organic solvent extraction and supercritical extraction methods).Pyrometallurgy technologies had relatively decent metal recovery rates but were associated with high energy consumption and atmospheric emission issues.Hydrometallurgical technologies were more environ-mentally friendly and efficient in recovering spent LIBs,although disposing of the wastewater generated from the process remained a challenge.In addition,the different industrial processes and various countries’related policies of recycling spent LIBs were investigated.In the end,the outlooks and future directions of recycling spent LIBs were proposed.

Progress,challenges,and prospects of spent lithium-ion batteries recycling:A review

The recycling and reutilization of spent lithium-ion batteries(LIBs)have become an important measure to alleviate problems like resource scarcity and environmental pollution.Although some progress has been made,battery recycling technology still faces challenges in terms of efficiency,effectiveness and environmental sustainability.This review aims to systematically review and analyze the current status of spent LIB recycling,and conduct a detailed comparison and evaluation of different recycling processes.In addition,this review introduces emerging recycling techniques,including deep eutectic solvents,molten salt roasting,and direct regeneration,with the intent of enhancing recycling efficiency and diminishing environmental repercussions.Furthermore,to increase the added value of recycled materials,this review proposes the concept of upgrading recycled materials into high value-added functional materials,such as catalysts,adsorbents,and graphene.Through life cycle assessment,the paper also explores the economic and environmental impacts of current battery recycling and highlights the importance that future recycling technologies should achieve a balance between recycling efficiency,economics and environmental benefits.Finally,this review outlines the opportunities and challenges of recycling key materials for next-generation batteries,and proposes relevant policy recommendations to promote the green and sustainable development of batteries,circular economy,and ecological civilization.

Recovery of Co and Li from spent lithium-ion batteries by combination method of acid leaching and chemical precipitation

Cathode material of spent lithium-ion batteries was refined to obtain high value-added cobalt and lithium products based on the chemical behaviors of metal in different oxidation states. The active substances separated from the cathode of spent lithium-ion batteries were dissolved in H2SO4 and H2O2 solution, and precipitated as CoC2O4·2H2O microparticles by addition of （NH4）2C2O4. After collection of the CoC2O4·2H2O product by filtration, the Li2CO3 precipitates were obtained by addition of Na2CO3 in the left filtrate. The experimental study shows that 96.3% of Co （mass fraction） and 87.5% of Li can be dissolved in the solution of 2 mol/L H2SO4 and 2.0% H2O2 （volume fraction）, and 94.7% of Co and 71.0% of Li can be recovered respectively in the form of CoC2O4·2H2O and Li2CO3.

Reductive acid leaching of valuable metals from spent lithium-ion batteries using hydrazine sulfate as reductant

Hydrazine sulfate was used as a reducing agent for the leaching of Li,Ni,Co and Mn from spent lithium-ion batteries.The effects of the reaction conditions on the leaching mechanism and kinetics were characterized and examined.97%of the available Li,96%of the available Ni,95%of the available Co,and 86%of the available Mn are extracted under the following optimized conditions:sulfuric acid concentration of 2.0 mol/L,hydrazine sulfate dosage of 30 g/L,solid-to-liquid ratio of 50 g/L,temperature of 80℃,and leaching time of 60 min.The activation energies of the leaching are determined to be 44.32,59.37 and 55.62 k J/mol for Li,Ni and Co,respectively.By performing X-ray diffraction and scanning electron microscopy in conjunction with energy dispersive X-ray spectroscopy,it is confirmed that the main phase in the leaching residue is MnO2.The results show that hydrazine sulfate is an effective reducing agent in the acid leaching process for spent lithium-ion batteries.

Progresses in Sustainable Recycling Technology of Spent Lithium-Ion Batteries

The number of lithium-ion batteries(LIBs)is steadily increasing in order to meet the ever-growing demand for sustainable energy and a high quality of life for humankind.At the same time,the resulting large number of LIB waste certainly poses safety hazards if it is not properly disposed of and will seriously harm the environment due to its inherent toxicity due to the use of toxic substances.Moreover,the consumption of many scarce precious metal resources is behind the mass production of batteries.In the light of severe environmental,resources,safety and recycling problems,recycling spent LIBs have become an essential urgently needed action to achieve sustainable social development.This review therefore critically analyses the value and the need for recycling of spent LIBs from a variety of resources and the environment.A range of existing technologies for recycling and reusing spent LIBs,such as pretreatment,pyrometallurgy,hydrometallurgy,and direct recycled methods,is subsequently summarized exclusively.In addition,the benefits and problems of the methods described above are analyzed in detail.It also introduces recycling progress of other LIB components,such as anodes,separators,and electrolytes,as well as the high-value cathode.Finally,the prospects for recycling LIBs are addressed in four ways(government,users,battery manufacturers,and recyclers).This review should contribute to the development of the recycling of used LIBs,particularly in support of industrialization and recycling processes.

Hydrometallurgical recycling of valuable metals from spent lithium-ion batteries by reductive leaching with stannous chloride

The reductant is a critical factor in the hydrometallurgical recycling of valuable metals from spent lithium-ion batteries(LIBs).There is limited information regarding the use of SnCl_(2) as a reductant with organic acid(maleic acid)for recovering valuable metals from spent Li-CoO_(2) material.In this study,the leaching efficiencies of Li and Co with 1 mol·L^(−1) of maleic acid and 0.3 mol·L^(−1) of SnCl_(2) were found to be 98.67%and 97.5%,respectively,at 60°C and a reaction time of 40 min.We investigated the kinetics and thermodynamics of the leaching process in this study to better understand the mechanism of the leaching process.Based on a comparison with H_(2)O_(2) with respect to leaching efficiency,the optimal leaching parameters,and the activation energy,we determined that it is feasible to replace H_(2)O_(2) with SnCl_(2) as a leaching reductant in the leaching process.In addition,when SnCl_(2) is used in the acid-leaching process,Sn residue in the leachate may have a positive effect on the re-synthesis of nickel-rich cathode materials.Therefore,the results of this study provide a potential direction for the selection of reductants in the hydrometallurgical recovery of valuable metals from spent LIBs.

Technology for recycling and regenerating graphite from spent lithium-ion batteries

With the annual increase in the amount of lithium-ion batteries(LIBs),the development of spent LIBs recycling technology has gradually attracted attention.Graphite is one of the most critical materials for LIBs,which is listed as a key energy source by many developed countries.However,it was neglected in spent LIBs recycling,leading to pollution of the environment and waste of resources.In this paper,the latest research progress for recycling of graphite from spent LIBs was summarized.Especially,the processes of pretreatment,graphite enrichment and purification,and materials regeneration for graphite recovery are introduced in details.Finally,the problems and opportunities of graphite recycling are raised.

Enhancement of leaching of cobalt and lithium from spent lithium-ion batteries by mechanochemical process

A mechanochemical method with SiO_(2)as the grinding aid was used to enhance the leaching efficiencies of Co and Li from spent lithium batteries(LIBs).Experiment results show that the optimal leaching efficiencies of 94.91%for Co and 97.22%for Li were obtained under the parameters of SiO_(2)/LiCoO_(2)mass ratio of 1:1,grinding speed of 500 r/min and grinding time of 30 min in citric acid.Characterization results indicate that the surficial properties of LiCoO_(2)were changed after mechanochemical grinding treatment due to the newly generated surfaces on LiCoO_(2).Meanwhile,the incompletely coordinated atomic structure and defective lattice structure lead to the activation of LiCoO_(2).The reduction effect of carbon black on Co^(3+)under the action of mechanical forces increases its leaching efficiencies in the citric acid solution.The proposed process was found efficiently to recover Co and Li from LiCoO_(2).

Direct regeneration of LiNi_(0.5)Co_(0.2)Mn_(0.3)O_(2) cathode material from spent lithium-ion batteries

At present,metal ions from spent lithium-ion batteries are mostly recovered by the acid leaching procedure,which unavoidably introduces potential pollutants to the environment.Therefore,it is necessary to develop more direct and effective green recycling methods.In this research,a method for the direct regeneration of anode materials is reported,which includes the particles size reduction of recovered raw materials by jet milling and ball milling,followed by calcination at high temperature after lithium supplementation.The regenerated LiNi_(0.5)Co_(0.2)Mn_(0.3)O_(2) single-crystal cathode material possessed a relatively ideal layered structure and a complete surface morphology when the lithium content was n(Ni+Co+Mn):n(Li)=1:1.10 at a sintering temperature of 920 0 C,and a sintering time of 12 h.The first discharge specific capacity was 154.87 mA·h·g^(-1) between 2.75 V and 4.2 V,with a capacity retention rate of 90% after 100 cycles.

Surplus energy utilization of spent lithium-ion batteries for high-profit organolithiums

It is challenging to efficiently and economically recycle many lithium-ion batteries(LIBs)because of the low valuation of commodity metals and materials,such as LiFePO_(4).There are millions of tons of spent LIBs where the barrier to recycling is economical,and to make recycling more feasible,it is required that the value of the processed recycled material exceeds the value of raw commodity materials.The presented research illustrates improved profitability and economics for recycling spent LIBs by utilizing the surplus energy in lithiated graphite to drive the preparation of organolithiums to add value to the recycled lithium materials.This study methodology demonstrates that the surplus energy of lithiated graphite obtained from spent LIBs can be utilized to prepare high-value organolithiums,thereby significantly improving the economic profitability of LIB recycling.Organolithiums(R-O-Li and R-Li)were prepared using alkyl alcohol(R-OH)and alkyl bromide(R-Br)as substrates,where R includes varying hindered alkyl hydrocarbons.The organolithiums extracted from per kilogram of recycled LIBs can increase the economic value between$29.5 and$226.5 kg^(−1) cell.The value of the organolithiums is at least 5.4 times the total theoretical value of spent materials,improving the profitability of recycling LIBs over traditional pyrometallurgical($0.86 kg^(−1) cell),hydrometallurgical($1.00 kg^(−1) cell),and physical direct recycling methods($5.40 kg^(−1) cell).

Cobalt recovery and microspherical cobalt tetroxide preparation from ammonia leaching solution of spent lithium-ion batteries

A process for recovering Co and preparing microspherical Co_(3)O_(4)through NH_(3)distillation and phase transformation from ammoniacal solution was investigated.As the basis of thermodynamics,the solubility of Co at different NH_(3)and CO_(3)^(2-)concentrations was studied,and then the effects of different NH_(3)distillation conditions on Co recovery rate were discussed.Over 94%Co and 96%NH_(3)were recovered through NH_(3)distillation,and the cobalt was precipitated in form of cobalt carbonate ammonium compound salt.Through the analysis of the formation mechanism of the precursor,the precipitation process of cobalt could be divided into two stages,and the cobalt precipitation rate was significantly accelerated in the second stage.In phase transformation,the effect of temperature on the roasted product was investigated.The microspherical Co_(3)O_(4)with a microporous structure was prepared at 300°C,and Co_(3)O_(4)with a mesoporous structure and high-spin state was obtained at 750°C.

Regeneration of Al-doped LiNi_(0.5)Co_(0.2)Mn_(0.3)O_(2) cathode material by simulated hydrometallurgy leachate of spent lithium-ion batteries

A uniform Al-doped LiNi_(0.5)Co_(0.2)Mn_(0.3)O_(2) cathode material was prepared using a coprecipitation method to take advantage of the positive effect of Al on regenerated NCM(Ni,Co,Mn)cathode materials and ameliorate cumbersome and high-cost impurity removal processes during lithium-ion battery recycling.When the Al^(3+) content in the leachate was 1 at.%with respect to the total amount of transition metals(Ni,Co,and Mn),the produced Al-doped NCM cathode material increased concentrations of lattice oxygen and Ni^(2+).The initial specific capacity at 0.1C was 167.4 mA·h/g,with a capacity retention of 79.1%after 400 cycles at 1C.Further,this Al-doped sample showed improved rate performance and a smaller electrochemical impedance.These findings provide a reference for developing industrial processes to resynthesize cathode materials with improved electrochemical performance by incorporating Al^(3+) impurities produced during lithium-ion battery recycling.

Extraction of lithium from the simulated pyrometallurgical slag of spent lithium-ion batteries by binary eutectic molten carbonates

The effective and low-temperature extraction of lithium from the pyrometallurgical slag of spent lithium-ion batteries(LIBs)remains a great challenge.Herein,potassium carbonate/sodium carbonate(K_(2)CO_(3)/Na_(2)CO_(3)),which could form a eutectic molten salt system at 720℃,was used as a roasting agent to extract lithium from pyrometallurgical slag.Lithium was successfully extracted from the slag by K_(2)CO_(3)/Na_(2)CO_(3) roasting followed by water leaching.Theoretical calculation results indicate that the lengths of Li-O bonds increase after K^(+)/Na^(+)adsorption,resulting in the easy release of Li^(+)from the LiAlSi_(2)O_(6) lattice after roasting with K_(2)CO_(3)/Na_(2)CO_(3).Thermogravimetry-differential scanning calorimetry results indicate that the eutectic phenomenon of K_(2)CO_(3) and Na_(2)CO_(3) could be observed at 720℃ and that the reaction of the slag and eutectic molten salts occurs at temperatures above 720℃.X-ray diffraction results suggest that Li^(+)in the slag is exchanged by K^(+)in K_(2)CO_(3) with the concurrent formation of KAlSiO_(4),while Na_(2)CO_(3) mainly functions as a fluxing agent.The lithium extraction efficiency can reach 93.87%under the optimal conditions of a roasting temperature of 740℃,roasting time of 30 min,leaching temperature of 50℃,leaching time of 40 min,and water/roasted sample mass ratio of 10:1.This work provides a new system for extracting lithium from the pyrometallurgical slag of spent LIBs.

Na_(2)SO_(4)-NaCl binary eutectic salt roasting to enhance extraction of lithium from pyrometallurgical slag of spent lithium-ion batteries

Effectively extracting lithium at a relatively low temperature from the slag produced by the pyrometallurgical treatment of spent lithium-ion batteries remains a great challenge,which limits the acquirement of lithium.Herein,we proposed a eutectic system to roast slag at a lower temperature based on sodium sulfate-sodium chloride(Na_(2)SO_(4)-NaCl)binary eutectic salts.The optimal roasting conditions are as follows:the slag was roasted at 750℃with a(SO_(4)^(2-)+Cl^(-))/Li+molar ratio of 5:1 for 120 min.Followed by aqueous leaching 5 min at room temperature with a water/roasted samples mass ratio of 30:1,it can get 97.07%lithium extraction efficiency.

Catalytic performance improvement of volatile organic compounds oxidation over MnO_(x) and GdMnO_(3) composite oxides from spent lithium-ion batteries:Effect of acid treatment

In this work,cathode materials of spent lithium-ion ternary batteries are recovered and used as metal precursor to prepare multi-metal oxides MnO_(x)(SY)and GdMnO_(3)(SY)via combustion method and sol-gel method,respectively.Furthermore,a series of MnO_(x)(SY)-n and GdMnO_(3)(SY)-n(n=0.05,0.10,1.00,4.00,n represents the dilute HNO_(3) concentration)catalysts are fabricated by acid treatment of MnO_(x)(SY)and GdMnO_(3)(SY)samples and catalytic activities of oxygenated VOCs oxidation over all the prepared catalysts are investigated.Catalytic evaluation results show that acid-treated MnO_(x)(SY)-0.10 and GdMnO_(3)(SY)-0.05 samples perform the optimum VOCs removal efficiency respectively,which may be attributed to their obvious enhancement of physicochemical properties.In detail,Mn O_(x)(SY)-0.10 and GdMnO_(3)(SY)-0.05 samples exhibit the larger specific surface area,bigger amount of surface high-valence metal ions(Mn^(4+),Co^(3+),Ni^(3+)),more abundant adsorbed oxygen species and better low-temperature reducibility,which can play a crucial role in the significant improvement of VOCs oxidation.In situ DRIFTS results imply that the possible main intermediates are-OCO,-COO and-C-O species produced during VOCs oxidation.Possible by-products are further determined via TD/GC-MS analysis.

Effective regeneration of high-performance anode material recycled from the whole electrodes in spent lithium-ion batteries via a simplified approach

Along with the extensive application of energy storage devices,the spent lithium-ion batteries(LIBs)are unquestionably classified into the secondary resources due to its high content of several valuable metals.However,current recycling methods have the main drawback to their tedious process,especially the purification and separation process.Herein,we propose a simplified process to recycle both cathode(LiCoO_(2))and anode(graphite)in the spent LIBs and regenerate newly high-performance anode material,CoO/CoFe2O4/expanded graphite(EG).This process not only has the advantages of succinct procedure and easy control of reaction conditions,but also effectively separates and recycles lithium from transition metals.The 98.43%of lithium is recovered from leachate when the solid product CoO/CoFe2O4/EG is synthesized as anode material for LIBs.And the product exhibits improved cyclic stability(890 mAh g^(-1) at 1 A g^(-1) after 700 cycles)and superior rate capability(208 mAh g^(-1) at 5 A g^(-1)).The merit of this delicate recycling design can be summarized as three aspects:the utilization of Fe impurity in waste LiCoO_(2),the transformation of waste graphite to EG,and the regeneration of anode material.This approach properly recycles the valuable components of spent LIBs,which introduces an insight into the future recycling.