Nickel and cobalt recycling from lithium-ion batteries by electrochemical processes

Recycling of spent lithium-ion batteries for a sustainable future: recent advancements

Lithium-ion batteries (LIBs) are widely used as power storage systems in electronic devices and electric vehicles (EVs). Recycling of spent LIBs is of utmost importance from various perspectives including recovery of valuable metals (mostly Co and Li) and mitigation of environmental pollution. Recycling methods such as direct recycling, pyrometallurgy, hydrometallurgy, bio-hydrometallurgy (bioleaching) and electrometallurgy are generally used to resynthesise LIBs. These methods have their own benefits and drawbacks. This manuscript provides a critical review of recent advances in the recycling of spent LIBs, including the development of recycling processes, identification of the products obtained from recycling, and the effects of recycling methods on environmental burdens. Insights into chemical reactions, thermodynamics, kinetics, and the influence of operating parameters of each recycling technology are provided. The sustainability of recycling technologies (e.g., life cycle assessment and life cycle cost analysis) is critically evaluated. Finally, the existing challenges and future prospects are presented for further development of sustainable, highly efficient, and environmentally benign recycling of spent LIBs to contribute to the circular economy.

Divalent Metal Ion Depletion from Wastewater by RVC Cathodes: A Critical Review

In this paper, a critical review of results obtained using a reticulated vitreous carbon (RVC) three-dimensional cathode for the electrochemical depletion of various divalent ions, such as Cu+2, Cd+2, Pb+2, Zn+2, Ni+2, and Co+2, often present in wastewater, has been carried out. By analyzing the kinetics and fluid dynamics of the process found in literature, a general dimensionless equation, Sh = f(Re), has been determined, describing a general trend for all the analyzed systems regardless of the geometry, dimensions, and starting conditions. Thus, a map in the log(Sh) vs. log(Re) plane has been reported by characterizing the whole ion electrochemical depletion process and highlighting the existence of a good correlation among all the results. Moreover, because in recent years, the interest in using this three-dimensional cathode material seems to have slowed, the intent is to revive it as a useful tool for metal recovery, recycling processes, and water treatments.

FeIII Chelated with Humic Acid with Easy Synthesis Conditions and Good Performance as Anode Materials for Lithium-Ion Batteries

In this work, we prepared a green, cheap material by chelating humic acid with ferric ions (HA-Fe) and used it as an anode material in LIBs for the first time. From the SEM, TEM, XPS, XRD, and nitrogen adsorption-desorption experimental results, it was found that the ferric ion can chelate with humic acid successfully under mild conditions and can increase the surface area of materials. Taking advantage of the chelation between the ferric ions and HA, the capacity of HA-Fe is 586 mAh·g-1 at 0.1 A·g-1 after 1000 cycles. Moreover, benefitting from the chelation effect, the activation degree of HA-Fe (about 8 times) is seriously improved compared with pure HA material (about 2 times) during the change-discharge process. The capacity retention ratio of HA-Fe is 55.63% when the current density increased from 0.05 A·g-1 to 1 A·g-1, which is higher than that of HA (32.55%) and Fe (24.85%). In the end, the storage mechanism of HA-Fe was investigated with ex-situ XPS measurements, and it was found that the C=O and C=C bonds are the activation sites for storage Li ions but have different redox voltages.

Thermodynamics of Li+-Crown Ether Interactions in Aqueous Solvent

Lithium ion-based batteries are ubiquitous in modern technology due to applications in personal electronics and high-capacity storage for electric vehicles. Concerns about lithium supply and battery waste have prompted interest in lithium recycling methods. The crown ether 12-crown-4 has been studied for its abilities to form stable complexes with lithium ions (Li⁺). In this paper, molecular dynamics simulations are applied to examine the binding properties of a 12-crown-4-Li⁺ system in aqueous solution. It was found that 12-crown-4 did not form stable complexes with Li⁺ in aqueous solution due to the binding geometry which was prone to interference by surrounding water molecules. In addition, the binding properties of sodium ions (Na⁺) to 12-crown-4 are examined for comparison. Subsequently, calculations were performed with the crown ethers 15-crown-5 and 18-crown-6 to study their complexation with Li⁺ as well as Na⁺. It was determined that binding was unfavorable for both types of ions for all three crown ethers tested, though 15-crown-5 and 18-crown-6 showed a marginally greater affinity for Li⁺ than 12-crown-4. Metastable minima present in the potential of mean force for Na⁺ render binding marginally more likely there. We discuss these results in the context of membrane-based applications of crown ethers for Li⁺ separations.

Metallurgical Aspects of Ni-Coating and High Temperature Treatments for FBG Spectrum Regeneration

The structural integrity of mechanical components is assessed by FBG sensors in many industrial fields. The FBG sensor has a relevant application at very high or low temperatures. To avoid the variability of the reflected spectrum and the mechanical properties degradation of the FBG sensor, metal coatings have been used to guarantee the grating's integrity in extreme temperature environments. Particularly, at high temperatures, Ni could be a suitable selection as a coating to improve the features of FBG sensors. Furthermore, it was demonstrated that Ni coating and high-temperature treatments can recover a broken, seemingly unusable sensor. In this work, two main objectives were pursued: first, the determination of the best operative parameters to achieve the most compact, adherent, and homogeneous coating; second, the correlation between the obtained morphology and structure and the FBG spectrum modification, once Ni was deposited on the FBG sensor. The Ni coating was deposited from aqueous solutions. By performing heat treatments of the Ni-coated FBG sensor, it was investigated how the wavelength (WL) varied as a function of temperature and how that variation was caused by the structural or dimensional change of the Ni coating.

Solvent Extraction for Separation of 99.9% Pure Cobalt and Recovery of Li, Ni, Fe, Cu, Al from Spent LIBs

In this work, hydrometallurgical recycling of metals from high-cobalt-content spent lithium-ion batteries (LIBs) from laptops was studied using precipitation and solvent extraction as alternative purification processes. Large amounts of cobalt (58% by weight), along with nickel (6.2%), manganese (3.06%) and lithium (6.09%) are present in LiCoO2 and Li2CoMn3O8 as prominent Co-rich phases of the electrode material. The pregnant leach solution (PLS) that was generated by leaching in the presence of 10% H2O2 using 50 g/L pulp density at 80 °C for 4 h contained 27.4 g/L Co, 3.21 g/L Ni, 1.59 g/L Mn and 3.60 g/L Li. The PLS was subjected to precipitation at various pH using 2 M NaOH but the purification performance was poor. To improve the separation of Mn and other impurities and in order to avoid the loss of cobalt and nickel, separation studies were carried out using a solvent extraction technique using di-(2-ethylhexyl) phosphoric acid (D2EHPA) and bis-(2,4,4-trimethylpentyl) phosphinic acid (Cyanex 272). Overall, this study examines the fundamentals of separating and synthesizing 99.9% pure Co sulfate from leach liquor of spent laptop LIBs with remarkably high cobalt content.

Green Recycling Methods to Treat Lithium-Ion Batteries E-Waste: A Circular Approach to Sustainability

E-waste generated from end-of-life spent lithium-ion batteries (LIBs) is increasing at a rapid rate owing to the increasing consumption of these batteries in portable electronics, electric vehicles, and renewable energy storage worldwide. On the one hand, landfilling and incinerating LIBs e-waste poses environmental and safety concerns owing to their constituent materials. On the other hand, scarcity of metal resources used in manufacturing LIBs and potential value creation through the recovery of these metal resources from spent LIBs has triggered increased interest in recycling spent LIBs from e-waste. State of the art recycling of spent LIBs involving pyrometallurgy and hydrometallurgy processes generates considerable unwanted environmental concerns. Hence, alternative innovative approaches toward the green recycling process of spent LIBs are essential to tackle large volumes of spent LIBs in an environmentally friendly way. Such evolving techniques for spent LIBs recycling based on green approaches, including bioleaching, waste for waste approach, and electrodeposition, are discussed here. Furthermore, the ways to regenerate strategic metals post leaching, efficiently reprocess extracted high-value materials, and reuse them in applications including electrode materials for new LIBs. The concept of "circular economy" is highlighted through closed-loop recycling of spent LIBs achieved through green-sustainable approaches.

Literature Review, Recycling of Lithium-Ion Batteries from Electric Vehicles, Part I: Recycling Technology

During recent years, emissions reduction has been tightened worldwide. Therefore, there is an increasing demand for electric vehicles (EVs) that can meet emission requirements. The growing number of new EVs increases the consumption of raw materials during production. Simultaneously, the number of used EVs and subsequently retired lithium-ion batteries (LIBs) that need to be disposed of is also increasing. According to the current approaches, the recycling process technology appears to be one of the most promising solutions for the End-of-Life (EOL) LIBs—recycling and reusing of waste materials would reduce raw materials production and environmental burden. According to this performed literature review, 263 publications about “Recycling of Lithium-ion Batteries from Electric Vehicles” were classified into five sections: Recycling Processes, Battery Composition, Environmental Impact, Economic Evaluation, and Recycling & Rest. The whole work reviews the current-state of publications dedicated to recycling LIBs from EVs in the techno-environmental-economic summary. This paper covers the first part of the review work; it is devoted to the recycling technology processes and points out the main study fields in recycling that were found during this work.

Novel electrochemically driven and internal circulation process for valuable metals recycling from spent lithium-ion batteries

The sustainable recycling of valuable metals from spent lithium-ion batteries (LIBs) is impeded by the issues of extensive chemicals consumption, tedious separation process and deficient selectivity. Here, novel electrochemically driven and internal circulation strategy was developed for the direct and selective recycling of valuable metals from waste LiCoO₂ of spent LIBs. Firstly, the waste LiCoO₂ can be efficiently dissolved by generated acid (H₂SO₄) during electro-deposition of Cu from CuSO₄ electrolyte. Then, Co²⁺ ions in the lixivium can be electrodeposited and recovered as metallic Co with a coinstantaneous regeneration of H₂SO₄ and regenerated acid can be reused as leachant without obvious shrinking of leaching capability based on circulating leaching results. Over 92% Co and 97% Li can be leached, and 100% Cu and 93% Co are recovered as their metallic forms under the optimized experimental conditions. Results of leaching kinetics suggest that the leaching of Co and Li is controlled by internal diffusion with significantly reduced apparent activation energies (E_a) for Li and Co. Finally, Li₂CO₃ can be recovered from Li⁺ enriched lixivium after circulating leaching. This recycling process is a simplified route without any input of leachant and reductant, and valuable metals can be selectively recovered in a closed-loop way with high efficiency.

Multivariate optimization of removing of cobalt(II) with an efficient aminated-GMA polypropylene adsorbent by induced-grafted polymerization under simultaneous gamma-ray irradiation

Nowadays, radiation grafting polymer adsorbents have been widely developed due to their advantages, such as low operating cost, high efficiency. In this research, glycidyl methacrylate monomers were grafted on polypropylene polymer fibers by simultaneous irradiation of gamma-ray with a dose of 20 kGy. The grafted polymer was then modified using different amino groups and tested for adsorption of cobalt ions in an aqueous solution. Finally, the modified polymer adsorbent with a high efficiency for cobalt ions adsorption was synthesized and tested. Different modes of cobalt ions adsorption were tested in other adsorption conditions, including adsorption contact time, pH, different amounts of adsorbent mass, and different concentrations of cobalt ions solution. The adsorbent structure was characterized with FT-IR, XRD, TG and SEM techniques and illustrated having an efficient grafting percentage and adsorption capability for cobalt removing by batch experiments. The optimum conditions were obtained by a central composite design: adsorbent mass = 0.07 g, initial concentration = 40 mg/L, time = 182 min, and pH = 4.5 with ethylenediamine as a modified monomer and high amination percentage. Kinetics and equilibrium isotherms observation described that the experimental data followed pseudo-second-order and Langmuir models, respectively. The maximum adsorption capacity from Langmuir isotherm capacity is obtained equal to 68.02 mg/g.

Development of a Two-Stage Pyrolysis Process for the End-Of-Life Nickel Cobalt Manganese Lithium Battery Recycling from Electric Vehicles

With the continuous promotion of electric vehicles, the pressure to scrap vehicle batteries is increasing, especially in China, where nickel cobalt manganese lithium (NCM) batteries have gradually come to occupy a dominant position in the battery market. In this study, we propose a two-stage pyrolysis process for vehicle batteries, which aims to effectively deal with the volatilization of organic solvents, the decomposition of lithium salts in the electrolyte and the removal of the separator material and polyvinylidene fluoride (PVDF) during battery recycling. By solving these issues, recycling is more effective, safe. Through thermogravimetric analysis (TGA), the pyrolysis characteristics of the battery’s internal materials are discussed, and 150 °C and 450 °C were determined as the pyrolysis temperatures of the two-stage pyrolysis process. The results show that in the first stage of pyrolysis, organic solvents EC (C4H3O3), DEC (C5H10O3) and EMC (C4H8O3) can be separated from the electrolyte. In the second stage, the pyrolysis can lead to the separator’s thermal decomposition. The gas products are alkane C2-C6, and the tar products are organic hydrocarbons C15-C36. Meanwhile, the solid residue of the battery’s internal material seems to be very homogeneous. Finally, the potential recovery value and pollution control countermeasures of the products and residues from the pyrolysis process are analyzed. Consequently, this method can effectively handle NCM vehicle battery recycling, which provides the basis for the subsequent hydrometallurgical or pyrometallurgical process for element recovery of the battery material.

Extraction Behavior of Acidic Phosphorus-Containing Compounds to Some Metal Ions: A Combination Research of Experimental and Theoretical Investigations

To provide feasible methods for the extraction of valuable metals from spent batteries or low-grade primary ores, the extraction behavior of some representative acidic phosphorus-containing compounds (APCCs) as extractants is evaluated from the perspective of experimental and theoretical investigations in this work. Aqueous solutions containing five metal ions, Ca(II), Co(II), Mg(II), Mn(II), and Ni(II), were made to simulate leaching liquids, and the extraction of these metals was investigated. A simplified calculated model was used to evaluate the interaction between each extractant and metal ions. The calculation results agree well with the experimental tests in trend. This work not only provides potential extractants for the extraction of valuable metals from spent batteries or low-grade primary ores but also demonstrates the practicability of the simplified calculation model.

Progress and Status of Hydrometallurgical and Direct Recycling of Li-Ion Batteries and Beyond

An exponential market growth of Li-ion batteries (LIBs) has been observed in the past 20 years; approximately 670,000 tons of LIBs have been sold in 2017 alone. This trend will continue owing to the growing interest of consumers for electric vehicles, recent engagement of car manufacturers to produce them, recent developments in energy storage facilities, and commitment of governments for the electrification of transportation. Although some limited recycling processes were developed earlier after the commercialization of LIBs, these are inadequate in the context of sustainable development. Therefore, significant efforts have been made to replace the commonly employed pyrometallurgical recycling method with a less detrimental approach, such as hydrometallurgical, in particular sulfate-based leaching, or direct recycling. Sulfate-based leaching is the only large-scale hydrometallurgical method currently used for recycling LIBs and serves as baseline for several pilot or demonstration projects currently under development. Conversely, most project and processes focus only on the recovery of Ni, Co, Mn, and less Li, and are wasting the iron phosphate originating from lithium iron phosphate (LFP) batteries. Although this battery type does not dominate the LIB market, its presence in the waste stream of LIBs causes some technical concerns that affect the profitability of current recycling processes. This review explores the current processes and alternative solutions to pyrometallurgy, including novel selective leaching processes or direct recycling approaches.

Biorecovery of cobalt and nickel using biomass-free culture supernatants from Aspergillus niger

In this research, the capabilities of culture supernatants generated by the oxalate-producing fungus Aspergillus niger for the bioprecipitation and biorecovery of cobalt and nickel were investigated, as was the influence of extracellular polymeric substances (EPS) on these processes. The removal of cobalt from solution was >90% for all tested Co concentrations: maximal nickel recovery was >80%. Energy-dispersive X-ray analysis (EDXA) and X-ray diffraction (XRD) confirmed the formation of cobalt and nickel oxalate. In a mixture of cobalt and nickel, cobalt oxalate appeared to predominate precipitation and was dependent on the mixture ratios of the two metals. The presence of EPS together with oxalate in solution decreased the recovery of nickel but did not influence the recovery of cobalt. Concentrations of extracellular protein showed a significant decrease after precipitation while no significant difference was found for extracellular polysaccharide concentrations before and after oxalate precipitation. These results showed that extracellular protein rather than extracellular polysaccharide played a more important role in influencing the biorecovery of metal oxalates from solution. Excitation–emission matrix (EEM) fluorescence spectroscopy showed that aromatic protein-like and hydrophobic acid-like substances from the EPS complexed with cobalt but did not for nickel. The humic acid-like substances from the EPS showed a higher affinity for cobalt than for nickel.

Design and analysis of surface plasmon resonance optical sensor for determining cobalt ion based on chitosan-graphene oxide decorated quantum dots-modified gold active layer

In this study, the incorporation of surface plasmon resonance (SPR) spectroscopy with novel chitosan-graphene oxide/cadmium sulphide quantum dots (CdS QDs) active layer for cobalt ion (Co²⁺) detection has been developed. The interaction of different Co²⁺ concentrations with the novel modified active layer was monitored using the SPR technique. From the SPR results, detection range, sensitivity, full width at half maximum (FWHM), detection accuracy (DA) and signal-to-noise ratio (SNR) have been analysed. The results showed the detection range of this optical sensor was 0.01 to 10 ppm, and it was saturated for higher concentration of Co²⁺. The sensitivity obtained was 0.1188 ppm^-1 for low concentration of Co²⁺ ranged from 0.01 to 1 ppm. The FWHM and DA were consistent for all concentration of Co²⁺, while the SNR of the SPR signal increased with the Co²⁺ concentration. The SPR angle shifts were also fitted using Langmuir, Freundlich and Sips (Langmuir-Freundlich) isotherm models, where Sips model fitted the best with the binding affinity of 0.939 ppm^-1. The results proved that the novel chitosan-graphene oxide/CdS QDs modified gold thin film can detect Co²⁺ via SPR spectroscopy.

Maleic, glycolic and acetoacetic acids-leaching for recovery of valuable metals from spent lithium-ion batteries: leaching parameters, thermodynamics and kinetics

Environmentally friendly acid-leaching processes with three organic acids (maleic, glycolic and acetoacetic) were developed to recover valuable metals from the cathodic material of spent lithium-ion batteries (LiCoO₂). The leaching efficiencies of Li and Co by the maleic acid were 99.58% and 98.77%, respectively. The leaching efficiencies of Li and Co by the glycolic acid were 98.54% and 97.83%, while those by the acetoacetic acid were 98.62% and 97.99%, respectively. The optimal acid concentration for the maleic acid-, glycolic acid- and acetoacetic acid-leaching processes were 1, 2 and 1.5 mol l^-1, respectively, while their optimal H₂O₂ concentrations were 1.5, 2 and 1.5 vol%, respectively. The optimal solid/liquid ratio, temperature and reaction time for the leaching process of the three organic acids was the same (10 g l^-1, 70°C, 60 min). The thermodynamic formation energy of the leaching products and the Gibbs free energy of the leaching reactions were calculated, and the kinetic study showed that the leaching processes fit well with the shrinking-core model. Based on the comparison in the leaching parameters, the efficacy and availability of the three acids is as follows: maleic acid > acetoacetic acid > glycolic acid.

A Fast Metals Recovery Method for the Synthesis of Lithium Nickel Cobalt Aluminum Oxide Material from Cathode Waste

An approach for a fast recycling process for Lithium Nickel Cobalt Aluminum Oxide (NCA) cathode scrap material without the presence of a reducing agent was proposed. The combination of metal leaching using strong acids (HCl, H2SO4, HNO3) and mixed metal hydroxide co-precipitation followed by heat treatment was investigated to resynthesize NCA. The most efficient leaching with a high solid loading rate (100 g/L) was obtained using HCl, resulting in Ni, Co, and Al leaching efficiencies of 99.8%, 95.6%, and 99.5%, respectively. The recycled NCA (RNCA) was successfully synthesized and in good agreement with JCPDS Card #87-1562. The highly crystalline RNCA presents the highest specific discharge capacity of a full cell (RNCA vs. Graphite) of 124.2 mAh/g with capacity retention of 96% after 40 cycles. This result is comparable with commercial NCA. Overall, this approach is faster than that in the previous study, resulting in more efficient and facile treatment of the recycling process for NCA waste and providing 35 times faster processing.

Molecular Electrostatic Potential: A New Tool to Predict the Lithiation Process of Organic Battery Materials

This work is pioneering to introduce molecular electrostatic potential (MESP) to investigate the interaction between lithium ions and organic electrode molecules. The electrostatic potential on the van der Waals surface of the electrode molecule is calculated, and then the coordinates and relative values of the local minima of MESP can be correlated to the Li binding sites and sequence on an organic small molecule, respectively. This suggests a gradual lithiation process. Similar calculations are extended to polymers and even organic crystals. The operation process of MESP for these systems is explained in detail. Through providing accurate and visualizable lithium binding sites, MESP can give precise prediction of the lithiated structures and reaction mechanism of organic electrode materials. It will become a new theoretical tool for determining the feasibility of organic electrode materials for alkali metal ion batteries.

Toward sustainable and systematic recycling of spent rechargeable batteries

A comprehensive and novel view on battery recycling is provided in terms of the science and technology, engineering, and policy.

Process for recycling mixed-cathode materials from spent lithium-ion batteries and kinetics of leaching

A "grave-to-cradle" process for the recycling of spent mixed-cathode materials (LiCoO₂, LiCo_1/3Ni_1/3Mn_1/3O₂, and LiMn₂O₄) has been proposed. The process comprises an acid leaching followed by the resynthesis of a cathode material from the resulting leachate. Spent cathode materials were leached in citric acid (C₆H₈O₇) and hydrogen peroxide (H₂O₂). Optimal leaching conditions were obtained at a leaching temperature of 90 °C, a H₂O₂ concentration of 1.5 vol%, a leaching time of 60 min, a pulp density of 20 g L^-1, and a citric acid concentration of 0.5 M. The leaching efficiencies of Li, Co, Ni, and Mn exceeded 95%. The leachate was used to resynthesize new LiCo_1/3Ni_1/3Mn_1/3O₂ material by using a sol-gel method. A comparison of the electrochemical properties of the resynthesized material (NCM-spent) with that synthesized directly from original chemicals (NCM-syn) indicated that the initial discharge capacity of NCM-spent at 0.2 C was 152.8 mA h g^-1, which was higher than the 149.8 mA h g^-1 of NCM-syn. After 160 cycles, the discharge capacities of the NCM-spent and NCM-syn were 140.7 mA h g^-1 and 121.2 mA h g^-1, respectively. After discharge at 1 C for 300 cycles, the NCM-spent material remained a higher capacity of 113.2 mA h g^-1 than the NCM-syn (78.4 mA h g^-1). The better performance of the NCM-spent resulted from trace Al doping. A new formulation based on the shrinking-core model was proposed to explain the kinetics of the leaching process. The activation energies of the Li, Co, Ni, and Mn leaching were calculated to be 66.86, 86.57, 49.46, and 45.23 kJ mol^-1, respectively, which indicates that the leaching was a chemical reaction-controlled process.

A common tattoo chemical for energy storage: henna plant-derived naphthoquinone dimer as a green and sustainable cathode material for Li-ion batteries

The burgeoning energy demands of an increasingly eco-conscious population have spurred the need for sustainable energy storage devices, and have called into question the viability of the popular lithium ion battery. A series of natural polyaromatic compounds have previously displayed the capability to bind lithium via polar oxygen-containing functional groups that act as redox centers in potential electrodes. Lawsone, a widely renowned dye molecule extracted from the henna leaf, can be dimerized to bislawsone to yield up to six carbonyl/hydroxyl groups for potential lithium coordination. The facile one-step dimerization and subsequent chemical lithiation of bislawsone minimizes synthetic steps and toxic reagents compared to existing systems. We therefore report lithiated bislawsone as a candidate to advance non-toxic and recyclable green battery materials. Bislawsone based electrodes displayed a specific capacity of up to 130 mA h g⁻¹ at 20 mA g⁻¹ currents, and voltage plateaus at 2.1–2.5 V, which are comparable to modern Li-ion battery cathodes.

The burgeoning energy demands of an increasingly eco-conscious population have spurred the need for sustainable energy storage devices, and have called into question the viability of the popular lithium ion battery.

Copper Impurity Effects on LiNi(1/3)Mn(1/3)Co(1/3)O2 Cathode Material

The crystal structure and electrochemical properties of LiNi1/3Mn1/3Co1/3O2 (NMC) synthesized from a lithium ion battery recovery stream have been studied previously. In this report, we study the Cu impurity effects on NMC in detail. The difference in crystal structures and electrochemical properties were examined for pure and copper impurity included products. Scanning electron microscopy figures show that the precursor particles of NMC are slightly bigger than that of NMC with copper impurity. After undergoing 150 cycles at 2C, X-ray diffraction refinements results show that the lattice parameters for impurity containing NMC and pure NMC change to different extents. Furthermore, due to the minor change of lattice parameters, copper-containing NMC offers a more stable capacity retention compared to pure NMC.

Hydrometallurgical recovery of metal values from sulfuric acid leaching liquor of spent lithium-ion batteries

Environmentally hazardous substances contained in spent Li-ion batteries, such as heavy metals and nocuous organics, will pose a threat to the environment and human health. On the other hand, the sustainable recycling of spent lithium-ion batteries may bring about environmental and economic benefits. In this study, a hydrometallurgical process was adopted for the comprehensive recovery of nickel, manganese, cobalt and lithium from sulfuric acid leaching liquor from waste cathode materials of spent lithium-ion batteries. First, nickel ions were selectively precipitated and recovered using dimethylglyoxime reagent. Recycled dimethylglyoxime could be re-used as precipitant for nickel and revealed similar precipitation performance compared with fresh dimethylglyoxime. Then the separation of manganese and cobalt was conducted by solvent extraction method using cobalt loaded D2EHPA. And McCabe-Thiele isotherm was employed for the prediction of the degree of separation and the number of extraction stages needed at specific experimental conditions. Finally, cobalt and lithium were sequentially precipitated and recovered as CoC2O4 ⋅ 2H2O and Li2CO3 using ammonium oxalate solution and saturated sodium carbonate solution, respectively. Recovery efficiencies could be attained as follows: 98.7% for Ni; 97.1% for Mn, 98.2% for Co and 81.0% for Li under optimized experimental conditions. This hydrometallurgical process may promise a candidate for the effective separation and recovery of metal values from the sulfuric acid leaching liquor.

Scenario-Based Development of Disassembly Systems for Automotive Lithium Ion Battery Systems

The rising number of lithium ion batteries from electric vehicles makes an economically advantageous and technically mature disassembly system for the end-of-life batteries inevitable. The disassembly system needs to cope with the size, the design and the remaining state of charge of the respective battery system. The complex design resulting from the number and type of connection elements challenges an automated disassembly. The realisation of an automated disassembly presupposes the consideration of elements from Design for Disassembly throughout the battery system development. In this paper a scenario-based development of disassembly systems is presented with varying possible design aspects as well as different amounts of end of life battery systems. These scenarios point out the resulting implications on battery disassembly systems in short, medium and long term. Using a morphological box the best option for each disassembly scenario is identified and framed in a disassembly system design. The disassembly systems are explained and the core elements are introduced. Newly developed and innovative disassembly tools, such as a robot that allows a hybrid human-robot-working-space and an advanced battery cell gripper are introduced. The gripper system for the battery cells enables with an integrated sensor an instant monitoring of the battery cell condition. The proposed disassembly element is verified in an experimental test series with automotive pouch cell batteries.

Environmental impact assessment and end-of-life treatment policy analysis for Li-ion batteries and Ni-MH batteries

Based on Life Cycle Assessment (LCA) and Eco-indicator 99 method, a LCA model was applied to conduct environmental impact and end-of-life treatment policy analysis for secondary batteries. This model evaluated the cycle, recycle and waste treatment stages of secondary batteries. Nickel-Metal Hydride (Ni-MH) batteries and Lithium ion (Li-ion) batteries were chosen as the typical secondary batteries in this study. Through this research, the following results were found: (1) A basic number of cycles should be defined. A minimum cycle number of 200 would result in an obvious decline of environmental loads for both battery types. Batteries with high energy density and long life expectancy have small environmental loads. Products and technology that help increase energy density and life expectancy should be encouraged. (2) Secondary batteries should be sorted out from municipal garbage. Meanwhile, different types of discarded batteries should be treated separately under policies and regulations. (3) The incineration rate has obvious impact on the Eco-indicator points of Nickel-Metal Hydride (Ni-MH) batteries. The influence of recycle rate on Lithium ion (Li-ion) batteries is more obvious. These findings indicate that recycling is the most promising direction for reducing secondary batteries’ environmental loads. The model proposed here can be used to evaluate environmental loads of other secondary batteries and it can be useful for proposing policies and countermeasures to reduce the environmental impact of secondary batteries.