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Recycling and Direct-Regeneration of Cathode Materials from
Spent Ternary Lithium-Ion Batteries by Hydrometallurgy: Status
Quo and Developing
Lizhen Duan
School of Metallurgical Engineering, Xi’an University of Architecture and Technology,
Xi’an 710055, China
Yaru Cui*
School of Metallurgical Engineering, Xi’an University of Architecture and Technology,
Xi’an 710055, China
*Email: <[email protected]>
Qian Li
School of Metallurgical Engineering, Xi’an University of Architecture and Technology,
Xi’an 710055, China
Juan Wang*
Xi’an Key Laboratory of Clean Energy, Xi’an University of Architecture and Technology,
Xi’an 710055, China
*Email: <[email protected]>
Chonghao Man
College of Engineering, The University of New South Wales, Sydney, NSW 2052,
Australia
Xinyao Wang
School of Metallurgical Engineering, Xi’an University of Architecture and Technology,
Xi’an 710055, China
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ABSTRACT
The cathodes of spent ternary lithium-ion batteries (LIBs) are rich in non-ferrous
metals, such as lithium (Li), nickel (Ni), cobalt (Co)and manganese (Mn), which are
important strategic raw materials and also potential sources of environmental
pollution. How to extract these valuable metals cleanly and efficiently from spent
cathodes is of great significance for sustainable development of LIBs industry. In the
light of low energy consumption, green and high recovery efficiency, this paper
provides an overview on different recovery technologies to recycle valuable metals in
cathode materials of spent ternary LIBs. And the development trend and application
prospects on recovery strategies for cathode materials in spent ternary LIBs are simply
predicted also. It is proved that the high economic recovery system of “alkaline
solution dissolution/calcination pre-treatment → H2SO4 leaching → H2O2 reduction →
co-precipitation regeneration NCM” will be the dominant stream for recycling retired
NCM batteries soon. Furthermore, the emerging advanced technologies, such as deep
eutectic solvents (DESs) extraction and one–step direct regeneration/recovery of NCM
cathode materials are preferred methods to substitute conventional regeneration
system in the future.
Keywords: spent ternary LIBs, valuable metals, recovery technologies, direct
recovery/regeneration, deep eutectic solvents
1. Introduction
In 21st century, mankind is suffering increasingly severe crisis of energy scarcity
and ecological environment deterioration. The worldwide usage of fossil fuels account
for 84.7% of global energy consumption in 2018, which is equivalent to 11.7436 billion
tons of oil (1-2). That means the global CO2 emissions especially from fossil fuel will
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continue to grow rapidly. It is crucial to explore green & renewable energy system,
such as wind energy, tidal energy and solar energy and energy storage batteries, etc.,
to replace fossil fuels. Among the popular new-energy sources, lithium-ion batteries
(LIBs), with excellent energy storage property, security and stability, are considered
as the most potential clean-sustainable energy storage equipment. LIBs are widely
used in energy storage fields such as zero-emission vehicles (mainly electric vehicles
(EVs), and plug-in electric vehicles (PHEVs)), computers and electronic communication
devices (3-6). The newly emerging model for super-performance LIBs, assembled with
specific complex 3D/porous/polyhedron geometric structure in cathode/anode
materials, is perfectly satisfied with the scale-up properties requirements for zero-
emission vehicles (3-5). The increasing requirement for new energy vehicles contribute
to the expansion of LIBs market. Statistics estimated that the world’s production of
LIBs will increase by 520% from 2016 to 2020 (7), and about 50 million electric buses
will run on the road by the end of 2027 (8). Therefore, as major electronic wastes, the
number of expired LIBs will increase inevitably. In China, the weight of retired LIBs
may even reach 500 thousand metric tons by the end of 2020 (9), and that of EU alone
will reach 13828 tons in 2020 (10). Since the harmful substances may damage
environment and the containing metals are precious resources, the recovery of retired
LIBs are bound to gain considerable social, economic and environmental benefit.
The cathodes of retired LIBs are rich in valuable non-ferrous metals such as lithium,
nickel, cobalt and manganese, which are secondary resources worth recycling.
Considering potential immense profit, researchers have been working hard to develop
various technologies to recycle precious metals in spent LIBs. The current recycling
technologies of valuable components from spent LIBs mainly include pyrometallurgy
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and hydrometallurgy strategy. Although pyrometallurgical recovery processes have
the advantages of short process, high efficiency and easy to achieve industrial
application, high energy consumption and toxic gases generation still limits its
development (11-14). In contrast, hydrometallurgical recovery processes have
attracted extensive attention due to low energy consumption, environmental
friendliness and high recovery efficiency (15-19). Leaching valuable elements using
chemical reagents is the core of hydrometallurgical recovery strategy. After leaching
process, valuable metals in leachate are extracted by chemical precipitation, solvent
extraction and ion-exchange, etc. (20-25). The conventional hydrometallurgical
process for waste electrodes recovery can be illustrated as follows: 1) acid-reductant
leaching + selective chemical precipitation; 2) sulphuric roasting+ acid leaching +
selective chemical precipitation; 3) mechanochemical activation leaching + selective
chemical precipitation, as shown in Table 1 (26-34). Nevertheless, it seemed that
sulphuric roasting or mechanochemical activating before leaching may complicate the
recovery process and decrease overall leaching rate. Based on the point of “waste
substance + waste substance→ rebirth resources”, Li et al. (35) developed an in-situ
recovery model of graphite, Li2CO3 and Co by “oxygen-free roasting with anode
graphite + wet magnetic separation” process, without pretreating or adding any other
chemical regents. However, this technique is not suitable for complex electrode
materials recovery. Prabaharan et al. (36) investigated an electro-chemical leaching
system of “lead as anode + electrode scraps as cathode +H2SO4 as leachate”, in which
the leaching rate of Mn, Cu and Co exceeded 96% through adjusting pH value.
Although it can perfectly achieve integrated recovery of valuable metals, the high
electricity consumption and recovery cost limits the spread of this method.
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Surprisingly, Gomaa et al. (37, 38) explored a new-multifunctional recovery method
to recycle ultra-trace Co2+ (about 3.05/4.7X10-8M) with visible selective ion extraction-
separation-detection. It can almost extract 100% Co2+ from leachate in only 10-15
min and the used ion-extractors after activation can regenerate and re-use in
repeated adsorption-desorption processes. Desorption by HCl eluting reagent, the
overall recovery rates of Co from waste LIBs or PCBs (printed circuit boards) are 98%
and 95.7% respectively.
NCM batteries consist of more valuable metals that are worth recycling compared
with traditional LiCoO2 and LiFePO4 batteries. However, few reports have been made
to systematically clarify recovery techniques for waste NCM materials. In order to avoid
loss of valuable resources and risk of second pollution, it is urgent to construct a
sustainable recycling model for valuable metals in cathodes of spent LIBs. This review
is aiming to introduce the progress of hydrometallurgical recycling cathode materials
from spent NCM batteries. Hydrometallurgical recovery strategy of waste LIBs can be
classified as three steps: (a) pretreatment: separate active substances; (b) leaching:
extract valuable metals from active substances with appropriate solvents;(c)
separation of valuable metals: extract valuable metals existed in leachate selectively
by different methods to obtain their metals or metallic compounds. The conventional
process flow for recycling NCM materials from waste LIBs by hydrometallurgy is shown
in figure 1. And correspondingly, the advantages, disadvantages, existing problems
and application status of different treatment methods are analysed. Furthermore,
advanced recovery technologies, deep eutectic solvents (DESs) extraction and crystal
repair direct-regeneration/recovery technology are emphatically illustrated. The
challenge and potential prospects on valuable metals recovery from ternary cathode
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materials of used LIBs by hydrometallurgy are prospected also. By comparing
advantages and disadvantages of different methods, it is expected that these
information will contribute to explore “economical-green-sustainable-high efficiency
leaching & separation & regeneration” recovery system for closed-circuit recycling of
LIBs.
2. NCM cathode materials for lithium-ion batteries
The LIBs are mainly divided into five types depending on the composition of cathode
materials: lithium iron phosphate battery (LiFePO4), lithium cobalt oxide battery
(LiCoO2), lithium manganese oxide battery (LiMn2O4), lithium nickel oxide battery
(LiNiO2), and lithium nickel cobalt manganese oxide battery (LiNixCoyMn1-x-yO2) (39-
43). Among them, layered LiNixCoyMn1-x-yO2 (NCM) materials become the leaders
because of excellent cycle/rate performance. Currently, there are five types of NCM
cathode materials that have been commercialized, NCM333 (LiNi1/3Co1/3Mn1/3O2),
NCM424 (LiNi0.4Co0.2Mn0.4O2), NCM523 (LiNi0.5Co0.2Mn0.3O2), NCM622
(LiNi0.6Co0.2Mn0.2O2) and NCM811 (LiNi0.8Co0.1Mn0.1O2) (44). It is predicted that the
NCM batteries will account for nearby 41% of the world’s LIBs market in 2025 (42).
The chemical characteristics and potential hazards of each component in ternary LIBs
are summarized in Table 2 (45-48). The NCM cathode materials are rich in lithium (Li),
nickel (Ni), cobalt (Co), manganese (Mn) and other strategic essential metals. The
heavy metals in waste LIBs will pose a huge threat to human health and ecological
environment (49). What’s more, the scarcity and high cost of nonferrous metals such
as Li and Co make it imperative to recycle ternary cathode materials from retired LIBs.
It is also reported that the global lithium resource reserves detected in 2018 are over
62 million tons, but China only account for 7%, about 4.5 million tons (50). As the
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core raw material for LIBs industry, the value of cobalt is as high as $ AUD115,000
per tonne (51, 52). How to efficiently extract these valuable non-ferrous metals from
retired LIBs is of great significance for green and sustainable development of batteries
industry.
3. Metallurgical recycling strategies for NCM
3.1 Recovery process
The advantages and disadvantages of different technologies for recycling spent
ternary LIBs are shown in Table 3 (53-57). Considering low energy consumption and
high recovery rate, currently, hydrometallurical recycling process is considered as a
preferred strategy to recover valuable metals from used cathode materials. While,
pyrometallurgical processes are usually used as a pre-treatment for leaching in
hydrometallurgical recycling.
3.2 Recovery process of hydrometallurgical method
(a) Pre-treatment
To prevent short circuit, spontaneous combustion and explosion during dismantling
waste LIBs, a pre-discharge work must be carried out before (58-60). The cathodes
consist of active material, current collector (Al foil) and binder (PVDF). Separating
high-purity active material is the key of pre-treatment process step. Table 4 shows the
pre-treatment methods and corresponding recycling effects of retired NCM batteries
(61-66). Considering separation efficiency and purity of recovered products, the
ultrasonic treatment and solvent dissolution methods have distinct advantage
compared with other methods. But ultrasonic method has high recovery cost due to
special requirements on equipment; and most organic solvents used in the solvent
dissolution methods are toxic and expensive. On contrast, the mechanical separation
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method has high degree of automatic operation and is easy to implement in industry.
However, it is difficult to avoid the components being mixed together, unable to be
separated fully in the next pulverization process, which may lower the purity of
recovered products. To improve extraction rate, reduction and roasting of cathode
materials are usually applied to convert the high valence metals of Co and Mn into low
ones that can be easily leached by chemical reagents. Considering recovery cost and
practical application, alkali dissolution and heat treatment are preferential pre-
treatment methods. The binders and current collectors of spent LIBs can be separated
simultaneously through heat calcination, and the obtained active materials even have
high purity and excellent crystal morphology and electrochemical performance.
(b) Leaching of valuable metals
Efficient leaching precious metals from active substances are the ultimate goal in
hydrometallurgical recovery process. Generally, acid leaching and bio-leaching are
applied to extract valuable metals (67), as shown in Figure 2.
The optimized process parameters and related leaching rate for extracting metals
from waste ternary LIBs are listed in Table 5 (68-75). It is proved that the leaching
ability of HCl in valuable metals is higher than that of other inorganic acid, such as
HNO3 and H2SO4 (68). And injecting suitable reducing agent into leaching system can
significantly strengthen the leaching efficiency. On compared, organic acids can
effectively increase the leaching rate of different metals while decrease the leaching
time. Due to environment-friendly and not introduce impurity ions, H2O2 is considered
as a popular candidate for reductants. However, H2O2 is easy to decompose under high
temperature, which weakens reduction effect (69). With better thermally stable,
NaHSO3 may be a favorable substitute.
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The leaching efficiency of valuable metals commonly depends on various factors,
including leaching methods/agents, pH value, composition of leaching system and
reductants, etc. To optimize leaching process and the subsequent separate and extract
process, researchers have made great efforts. Liu et al. (76) developed a new method
of pre-reduction roasting combined with two-step leaching to extract metals from
waste NCM cathodes. Transition metals ions of Mn4+ and Co3+ were converted into low-
valence ions of Mn2+ and Co through pre-reduction roasting, with 93.68% leaching
rate of Li in water leaching step and almost 99.6% leaching rate of Mn, Ni and Co in
H2SO4 leaching step. Zhuang et al. (77) studied the leaching property of mixed-acid
(phosphoric acid + citric acid) on valuable metals of used NCM materials. Without
adding any reductants, the leaching cost of raw materials is 37.81% lower than that
of the single acid leaching studied by Sun et al. (74,77). Under optimized conditions,
the leaching efficiency of Li, Ni, Co and Mn were up to 100%, 93.38%, 91.63% and
92.00%, respectively.
Besides conventional acid leaching, researchers have done a lot of works on
biological leaching (78-80). The leaching rates of waste NCM cathodes by bacteria in
literatures are summarized in Table 6 (81-86). Bioleaching technology mainly lies on
the organic/inorganic acids produced by decomposition of bacteria to leach valuable
metals. The bacteria leaching is characterized by extremely high selectivity for Li, with
leaching rate approaching 100%. Xin et al. (86) explored bio-leaching property on
different metals of three leaching system (as shown in Table 6). It was found that the
leaching rates of Li and Mn in MS-MC system were more than 95%, while that of Co
and Ni were only 40%. The bioleaching mechanism revealed that Li+ in NCM material
was released through biogenic acid dissolution, while transition metal ions Mn4+, Co3+
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and Ni3+ must be reduced to Mn2+, Co2+ and Ni2+ before acid leaching. It was also
observed that Fe2+ in MS-MC system contributed to reduce insoluble transition metal
ions into soluble low valence ions. That means the high-valence transition metal ions
can be effective dissolved through interaction of reduction and acid leaching by
bacteria. Lowering pH value of the leaching system is an effective means to accelerate
the cells growth during bioleaching stage, which can ensure sufficient sulfuric acid and
normal circulation of Fe2+/Fe3+ (86). Through controlling the system’s pH, the leaching
efficiency of the above metals were all over 95%.
(c) Extraction of valuable metals
There are mainly three separation methods, including selective precipitation, solvent
extraction and ion-exchange, to extract valuable metals from leachate. Due to simple
and easy to achieve industrial application, chemical precipitation is widely used.
Element of Li in leachate is usually recycled in the form of Li2CO3 by selective
precipitation, while Co, Mn and Ni can be separated by chemical precipitation or solvent
extraction (87-89), which can be reused as raw materials in LIBs or other fields. And
the process parameters of chemical precipitation in literatures are summarized in Table
6 (90). Mreshram et al. (91) extracted valuable metals from H2SO4 leachate by
selective precipitation. The CoC2O4·2H2O was extracted from leaching solution by
oxalic acid, then precipitates of MnCO3, NiCO3, and Li2CO3 were obtained by controlling
pH to 7.5, 9, and 14, respectively. Granata et al. (92) found that the order of different
extractants affected the separation efficiency of metals in leachate. The best recovery
rates reached above 90% with P204 (D2EHPA) to extract manganese first, followed by
co-extraction of cobalt and nickel with Cyanex 272.
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It was illustrated that reduction roasting is beneficial to improve the leaching rate of
non-ferrous metals. Zhang et al. (93) established a process of “reduction roasting →
H2O-CO2 leaching → H2SO4 leaching → evaporation and crystallization” to recover
valuable metals in waste NCM materials, as shown in Figure 3. The related leaching
mechanism and graphical illustration of recycling process are further illustrated in
Figure 4 (93). After reduction roasting, the phases in the cathode material were
converted into Li2CO3, Ni, Co and MnO, and corresponding leaching effect of different
metal was improved simultaneously (as the Figure 4(n) showed). For leaching system
containing gas, CO2 has significant influence on the leaching rate of Li. The solubility
of Li was improved by 47%after inputting CO2 to leaching system. Through controlling
the operation conditions of flow rate of CO2, pH and leaching temperature, Li was
selectively extracted as Li2CO3 by carbonic acid leaching combing evaporative
crystallization, while the elements of Ni, Mn and Co were deactivated and transformed
into leaching residues. The re-produced Li2CO3, possessing outstanding pureness and
submicron-scale stick morphology, can be directly used as lithium source to prepare
cathode materials of LIBs. After that, the other valuable metals in the leach residues
were recovered and extracted in the form of sulphate (MeSO4, Me=Mn, Ni and Co) by
H2SO4 leaching, with a high recovery rate of 96%.
In general, the leaching solution consists of complex components with different
properties. So combined separation methods are adopted to improve the overall
recovery efficiency (94). Chen et al. (94) developed an efficient process to extract
valuable metals from leachate based on two-step precipitation combined with solvent
extraction, as shown in Figure 5. The C4H8N2O2 was used to precipitate 98% nickel
from hydrochloric acid leachate firstly. And 97% cobalt was selectively precipitated as
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CoC2O4·2H2O with (NH4)2C2O4. Then, 97% Mn2+ was recovered as MnSO4 by extracting
with D2EHPA solvent, and 89% of the lithium was precipitated by Na3PO4 to form
Li3PO4.
4. Regeneration technologies of NCM cathode materials
4.1 Regeneration of NCM from leachate
Sustainable recovery and regeneration of NCM materials from leaching solution is
current main trend for exhausted LIBs recovery. Common methods to synthesize
cathode materials include chemical co-precipitation, high temperature solid phase,
hydrothermal synthesis, sol-gel, microwave synthesis and electrostatic spinning
method, etc. (95-100). And the parameters of re-synthesis methods to regenerate
NCM cathode materials from leachate are summarized in Table 7(61, 101-107).
The NCM cathode materials regenerated by hydrometallurgical process hold superior
crystal morphology and rate/cycle performance, whose electrochemical performance
are comparable to that of commercial NCM materials (102,104). The conventional
hydrometallurgical regeneration process to prepare NCM materials is as follows:
leaching liquid → co-precipitation→ solid phase synthesis at high temperature, as
shown in Figure 6. In the regeneration process, appropriate amounts of cobalt salts,
manganese salts, nickel salts and lithium salts are added according to actual
stoichiometry composition of NCM materials.
Li et al. (108) re-synthesized NCM333 (R-NCM) materials from cathode material’s
leaching liquids by one-step sol-gel method, and the related details and recycling
mechanism are showed in Figure 7 and Figure 8 (108). In the recovery system, the
H2O2 is used as reducing agent, and the lactic acid plays as leaching agent in leaching
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stage and chelating agent in regeneration stage respectively. The mechanism of
leaching stage can be proved as follows:
3LNi1/3Co1/3Mn1/3O2 (s)+9C3H6O3(aq) +1/2H2O2(aq) →3C3H5O3Li(aq)+(C3H5O3)2 Ni(aq)
+ (C3H5O3)2 Co(aq)+ (C3H5O3)2 Mn(l)+5H2O+O2(g) (4-1)
Under the optimal conditions (lactic acid=1.5M, s/d=20g·L-1, H2O2=0.5vol%,
T=343K), the leaching efficiency of the metals reached 98%. Electrochemical results
proved that the re-synthesized NCM333 (R-NCM) cathode material held excellent
reversible discharge capacity of 138.2 mAh·g-1, whose capacity retention reached 96%
at 0.5 C after 100 cycles (105). Due to low charge-transfer resistance of regenerated
NCM333 (R-NCM, Rct=58.78Ω) compared with fresh NCM333 (F-NCM, Rct=70.02Ω),
which can provide higher lithium ion diffusion coefficient (DLi+) and faster Li+
intercalation/de-intercalation kinetic properties, the electrochemical performance
especially cycle capability of R-NCM is self-evident higher than that of F-NCM. It is
indicated that chelating agent of lactic acid can efficiently recycle and re-synthesize
NCM materials by sol-gel method with closed-loop recovery process.
4.2 Integrated high value utilization of electrode scraps
In industrial production of LIBs, a lot of cathode scraps are produced (89), and
difficult to be utilized. Since those cathode scraps are not assembled into batteries,
the active materials in them maintain superior electrochemical performance. Efficient
recycling valuable component in these electrode scraps embodies both economic and
environmental benefits.
Zhang et al. (109) developed a representative one-step recovery technology to
regenerate NCM material from electrode scraps. The main recovery process contains
detaching active materials from Al foil and direct re-preparing NCM cathode materials
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by state solid reaction, as shown in Figure 9 (109). Pre-treated with direct calcination
(DC), solvent dissolution (SD) and basic solution dissolution (BD) methods, the re-
birth NCM samples presented diverse properties on electrochemical performance.
Interestingly, it was found that different quantity of LiF compound emerged on the
surface of regenerated NCM samples under pre-treated by DC/BD methods, as
resultants of HF released from PVDF reacted with Li element. It showed that the re-
prepared cathode materials directly calcined at 600°C (CD-600) exhibited uniform
spherical particles and superior cycle performance, with initial discharge capacity of
145.4 mAh·g-1 and capacity retention of 96.7% at 0.2C after100 cycles,
correspondingly. As the literatures proved that the emergence of suitable amount of
LiF contributes to hinder side reactions between NCM materials and electrolyte, which
could strengthen the structure stability of the recovered NCM materials (110-113).
4.3 Potential and challenge of mediate/direct regeneration method
The leaching-regeneration system, without intricate processes to remove impurities
and separate various metals, has caught researchers’ attention. With majority mature
technologies of co-precipitation, solvent dissolution and sol-gel, etc., the
hydrometallurgical recycle pattern is feasible to achieve industrial application. As
mentioned above, separation of active materials and leaching of valuable metals play
an important role in leaching-regeneration system. In fact, there are still low content
of impurities such as Al and Mg existed in the leachate. One recovery idea is employing
such impurities as doped metals to modify regeneration NCM materials, avoiding the
potential damage of impurities and purification treatment. And the excellent
electrochemical performance of regenerated Al/Mg-doped NCM materials (105,107)
are showed in Table 8. Furthermore, how to strictly control production conditions and
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identify the optimal residual content of impurities is an imminent problem need to be
resolved. Thus, there is still a long way to go before building recycle system with
superior leaching rate and efficacious separation of overall metals.
Another interesting recovery idea is using smelting slag as coated material source to
enhance the electrochemical performance of regenerated NCM materials. For instance,
coating with V2O5 produced from vanadium-containing slag, the regenerated NCM
samples (106) presented high cycle performance, as shown in Table 8. Meanwhile,
the general acid-roasting process (15) combines with one-step or hierarchical leaching
technology is worth to be considered.
In addition, as a non-damaged restoration technology, the direct regeneration
technology, also named re-construction of crystal structure, is different from the
hydrometallurgical leaching-regeneration system. This integrated high value utilization
technology can efficaciously avoid attack of active materials from multiple chemical
reagents in leaching and extracting processes. Besides, this simple and sustainable
one-step recover technology is conductive to realize high value re-use and recycling
of secondary resources, effectively cutting down the recovery cost. Last but most
important, the directly regenerated NCM samples hold excellent charge/discharge
capacity, superior cycle/rate performance, even comparable to that of commercial NCM
materials. Accordingly, one-step recycling or direct re-synthesis NCM materials are
considered as most favourable and influential hydrometallurgical recycling strategies
for retired LIBs or cathode scarps, at present. However, there are still immense
challenges before successful industrial application. For example, the green-simple
technology is needed to be further explored for efficiently detaching active materials
from Al foils, without destructing both crystalline particles and Al foils. In addition, it
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is high time that new methods should be developed for direct regeneration of different
types of NCM materials except high temperature solid phase method. Crucially, it is
imperative to build a closed-circuit recycling mode for all valuable components, such
as Al foils, PVDF and active materials via direct regeneration technology.
5. The latest recovery technologies of NCM cathode materials
5.1 Extractive methods based on deep eutectic solvents
Compared with the traditional extractants, deep eutectic solvents (DESs) have the
remarkable advantages of non-toxic, cheap and biodegradable, and extremely high
dissolution and reduction capability for metal oxides (114,115). However, there are
few reports on recycling electronic waste using deep eutectic solvents. As far as I see,
Tran et al. (116) first applied DESs to recycle cathode materials from waste LIBs. The
adopted DESs were synthesized by choline chloride and ethylene glycol, and the
possible synthesis reaction is as follows:
[HOC2H4N(CH3)3]++[Cl]-+n(HOCH2CH2OH)→[HOC2H4N(CH3)3]
++
(HOCH2CH2OH)n[Cl]- (5-1)
The Al foil and binder PVDF were recovered respectively while valuable metals were
extracted by DESs. The results showed that the leaching rate of cobalt in LiCoO2
cathode material was as high as 99.4% at 180°C, which was comparable to that of
traditional leaching agents such as sulfuric acid (99.70%) (70) and formic acid
(99.96%) (72). Cobalt in the DESs liquids can be recovered as Co3O4 by
electrodeposition and calcination.
Wang et al. (117) developed a recycling process using DESs to detach active
substances and Al foil of retired LIBs, as the recovery flow shown in Figure 10. And
the specific synthesis reaction of DESs is as follows:
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[HOC2H4N(CH3)3]++[Cl]-+n(CH2OHCHOHCH2OH)→[HOC2H4N(CH3)3]
++
(CH2OHCHOHCH2OH)n[Cl]- (5-2)
The DESs attacked the hydrogen atoms in PVDF molecular chain, forming
unsaturated double bonds, which were further oxidized into hydroxyl and carbonyl to
construct an unsaturated ketone structure on the molecular chain. Therefore, PVDF
was forced to deactivate and dissolve, the active materials and Al foil were separated
successfully. Hence, it can be indicated that DESs have great potential in regenerating
of cathode materials. High selectivity of valuable metals is the key to promote leaching
performance of DESs in recycling spent LIBs.
5.2 Technology of recovery NCM particles
Despite high recovery rates of R-NCM from leaching solution, electrochemical
performance is damaged to some extent due to inevitable contacting with organic
solvent during the treatment process. In the future, the recovery technologies that
show low efficiency must be avoided. Sieber et al. (118) directly recovered NCM
particles from used cathode scraps. The active material was detached from the Al foil
by strong stirring in water to maintain the electrochemical performance and
morphological characteristics of NCM particles. However, during the separation
process, side reactions occurred when the NCM cathode contacted with water, resulting
in a rapid increase in pH value and degradation of NCM particles followed by forming
of Al(OH)3 precipitate and LiAl(OH)4. The main chemical reactions during separation
stage are as follows:
2Al+2OH-+10H2O → 2[Al(OH)4(H2O)2]-+3H2 (5-3)
[Al(OH)4(H2O)2]- − H+ ⇄ [Al(OH)5(H2O)]2- − H+ ⇄ [Al(OH)6]3- (5-4)
2H++2Al + 2[Al(OH)4]-+4H2O → 4Al(OH)3 + 3H2 (5-5)
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Li+ + [Al(OH)4]- → LiAl(OH)4 (pH> 11) (5-6)
Such side effects can be avoided by adjusting pH value with superior buffer solution,
aiming to detach active materials from Al foil and hinder degradation of NMC particles.
Under the control of buffer solution, the Al foil was successfully dissolved into solution
while NCM particles were well-preserved.
6. Conclusions and overlook
The waste cathode materials in LIBs contain valuable metals, which can be recycled
by hydrometallurgical process due to low energy consumption, environmental friendly
and excellent recovery efficiency. Based on the analysis and summary of
hydrometallurgical recycling process, the following conclusions are drawn:
(1) In view of economy and industrial application, the following flow is considered
as the most competitive process to recycle valuable metals from waste cathode
materials: alkaline solution dissolution/calcination treatment → reductant (H2O2) →
sulphuric acid leaching → co-precipitation → re-synthesis at high temperature.
(2) The leaching capability of reductant organic acid is greater than that of
inorganic acid leaching united with reductants. Bacterial leaching shows high selectivity
for lithium, which can be selected to recycle high purity lithium-containing products.
(3) In the stage of extracting valuable metals, the combination recovery process
can complement each other, which contributes to improve the quality of the recycled
products.
(4) The deep eutectic solvents (DESs) separation technology can achieve efficient
overall recovery of valuable components from spent LIBs, which is conducive to
sustainable development of society. The high efficient direct-regeneration or direct-
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recovery of NCM materials will face to huge challenges and potential. In the future,
both of them will become research hotspots in exhausted LIBs recovery field.
Acknowledgements
This work was supported by Natural Science Foundation of China (No.51674186);
Natural Science Foundation of Shaanxi Province (No. 2020JQ-679); Key laboratory
project of education department of Shaanxi Province (No. 2018GY-166, 2019TD-019,
2019TSLGY07-04); Foundation of Xi’an Key Laboratory of Clean Energy (No.
2019219914SYS014CG036).
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The Authors
Lizhen Duan obtained her B.S. Degree in metallurgical engineering,
Xi’an University of Architecture and Technology, in 2018. She is
currently a candidate of M.D. at the School of Metallurgical
Engineering, Xi’an University of Architecture and Technology. Her
research interest is focused on cathode material for lithium-ion
batteries.
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Dr Yaru Cui, professor of School of Metallurgical Engineering in Xi’an
University of Architecture and Technology. She was conferred Ph.D.
degree in 2011, and was afforded the opportunity working in School of
Materials Science and Engineering, the University of New South Wales
of Australia, as a visiting fellow for one year. Her main research
interests covered metallurgical preparation of functional materials and
recycling technologies for metallurgical residues etc. At present, she
has authored or co-authored more than 70 journal publications.
Dr Qian Li obtained her PhD in Metallurgical Engineering, the Central
South University, in 2013. Then she worked as a lecturer in School of
Metallurgical Engineering at Xi’an University of Architecture and
Technology, China. She is mainly engaged in research and technology
of solar thin film cells, functional materials, sodium-ion battery and
lithium-ion battery. She has authored or co-authored more than 20
academic papers, 5 licensed patents.
Dr Juan Wang is a Distinguished Fellow and a Team Leader at
Shaanxi Key Laboratory of Nanomaterials & Nanotechnology,
China. She received her Ph.D. degree in materials science from
Xi’an University of Architecture & Technology, China, in 2009.
She is currently a professor and doctoral supervisor of the School
of Mechanical and Electrical Engineering, Xi’an University of
Architecture & Technology. She has authored or co-authored
over 50 papers in peer-reviewed journals related to the field of
energy and materials.
Chonghao Man obtained his B.S. Degree in condensed matter
physics, Southeast University of China, in 2018. Currently, he is
a MS candidate at the College of Engineering, the University of
New South Wales of Australia, major in information technology.
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Xinyao Wang obtained his B.S. Degree in metallurgical
engineering, Xi’an University of Architecture and Technology in
2019. He is currently pursuing his M.D. at the School of
Metallurgical Engineering, Xi’an University of Architecture and
Technology under the supervision of Prof. Yaru Cui. His main
research is focused on recycling waste lithium-ion batteries.
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<Tables>
Table I Summary of techniques for recovery and separation valuable metals from spent ternary lithium-ion
batteries [26-34]
Type of LIBs
Leaching system (reagents+ solid/Liquid/(g/L)+ temperature/K+time/min)
Leaching rate/% Extraction method(reagents) +Recovered products(recovery rate/purity/%)
Ref.
LiCoO2 acid + reductant leaching + selective chemical precipitation 1.5MH3Cit+0.4g/g tea waste+30+363+120
Co:96/Li: 98 selective precipitation(H2C2O4/H3PO4) + CoC2O4·2H2O(99/-)+ Li3PO4(93/-)
[26]
2MH3Cit+0.6g/g H2O2+50+343+80 Co:98/Li: 99 1.5MH3Cit+0.4g/g phytolacca americana+40+353+120 Co:83/Li: 96
NCM523 mechanochemical leaching + selective precipitation mechanochemical leaching Na2S·9H2O+15min+600rpm-water leaching+/+298+30
Li: 95.10 selective precipitation (Na2CO3) + Li2CO3 (-/99.96)+ Ni0.5Mn0.3Co0.2(OH)2
[27]
LiCoO2 mechanochemical activation leaching + selective precipitation mechanochemical activation (EDTA/600rpm/240min) +water leaching+/+298+/
Co:98/Li: 99 selective precipitation (NaOH/Na2CO3) + Co3O4 (about94/-)+ Li2CO3
[28]
LiCoO2 acid + reductant leaching + selective chemical precipitation 2% v/vH3PO4 & 2% v/vH2O2 +8+363+60
Co/Li: about 99 selective precipitation (H2C2O4/NaOH) + CoC2O4·2H2O (99/97.8)+ Li3PO4(88/98.3)
[29]
Mixed-type
sulphuric roasting+ acid leaching Before leaching: sulfuric acid baking:2MH2SO4+573k+30min Leaching step1: H2O+/+348+60 Leaching step1:1MH2SO4+0.5MHNO3+plus glucose+/+323+45
overall recovery efficiency: about Co:90.5/Li:93.2 Ni:82.8/Mn: 77.7
-- [30]
LiCoO2 acid + reductant leaching 1.0Mcitric acid+8v/v% H2O2+40+343+70
Co/Li: about 99 -- [31]
LiCoO2 acid + reductant leaching 3MH2SO4+0.4g/g plus glucose +25+368+120 3MH2SO4+0.4g/g cellulose+25+368+120 3H2SO4+0.4g/g sucrose +25+368+120
Co:98/Li: 96 Co:54/Li: 100 Co:96/Li: 100
-- -- --
[32]
Spent LIBs
acid + reductant leaching + selective chemical precipitation 1.5Mcitric+0.5g/g D-glucose+20+353+120
Co:92/Li:99 Ni:91/Mn:94
precipitation method(C4H8N2O2/H2C2O4/H3PO4) + Ni(C4H6N2O2)2+CoC2O4+ Li3PO4
[33]
LiFePO4 acid + reductant leaching + selective chemical precipitation 0.5H3PO4+/+273+60
Co/Li: over 95 evaporation and precipitation (ethanol) + FePO4·2H2O + LiH2PO4
[34]
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Table 2 Chemical properties and potential environment pollution of
component materials from spent ternary lithium-ion batteries [45-48]
Material Constitute Content,% Chemical properties Potential environment pollution
Cathode material
LiNixMnyCo1-x-yO2 25-30 Reacting with acids and bases, and producing heavy metals
Heavy metals pollution
Anode material
Graphite/Carbon 14-19 Producing toxic gases such as CO and dust particles under combustion
Toxic gases and dust
Casing Stainless steel/Plastic
20-25 Hardly degradable White pollution
Electrolyte LiPF6、LiBF4 LiClO4、LiAsF6
10-15 Strongly corrosive, releasing toxic gases in contact with water or high temperatures
Produceing toxic gases, polluting the air and damaging human health
Electrolyte solvent
EC、EMC DMC、PC
- Producing CO under combustion
Harm to human health through skin and respiratory contact with organic compounds
Cu foil Cu 5-9 - Heavy metals pollution Al foil Al 5-7 - Heavy metals pollution Separator PP/PE - - Organic pollution Binder PVDF - - Fluorine pollution
Table 3 The advantages or disadvantages of pyrometallurgical and
hydrometallurgical method [53-57]
Item Pyrometallurgical method Hydrometallurgical method Process Calcination Leaching, purification, separation and
extraction Recycling methods
High temperature reduction/Sulfatizing roasting /Repair and regeneration
Acid leaching, bioleaching/ Chemical precipitation/ Solvent extraction/Ion exchange/ Repair and regeneration
Operating temperature
573-1273K 298-353K
Cost High Low Advantages High efficiency, large processing
scale, and easy to achieve industrial applications, no waste water and sludge
Low energy consumption, mild operating conditions, high recovery rate, multiple processing methods, high selectivity, low exhaust emissions
Disadvantages High energy consumption, producing toxic waste gas(CO/CO2/SO2/HF), low recovery rate and low selectivity, single processing method, high temperature operating system
Some chemicals are poisonous, waste liquid problem, long process, complex separation process
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Table 4 Parameters and separation rate of pre-treatment methods for spent
LIBs in literature [61-66]
Type of LIBs Pretreatment methods
Reagents/ Temperature/K
Recovery rate of scrap materials/%
Separated substance /Purity/%
Ref.
LiNi1/3Co1/3Mn1/3O2 Solvent dissolution
Trifluoroacetic acid
- Al foil [61]
LiNi1/3Co1/3Mn1/3O2 Heat treatment Scraping+Water leaching
393 313
- PVDF Al foil
[62]
LiNi1/3Co1/3Mn1/3O2 Solvent dissolution
Dimethyl carbonate
99 Al foil ,PVDF
[63]
LiNi1/3Co1/3Mn1/3O2 Ultrasonic cleaning
N-methyl-2-pyrrolidone&343
99 PVDF, Al foil
[64]
LiNixCoyMnzO2 Basic solution dissolution
1.5 M NaOH - Al foil [65]
Laptop LIBs Heat treatment 523-573 - Al foil [66]
Table 5 Optimal leaching parameters and corresponding leaching rate of
metals from active material by acid leaching [68-75]
Type of LIBs
Leaching reagents
Reducta-nts
Solid/L-iquid /(g/L)
Tempera-ture /K
Time /min
Leaching rate/% Ref.
NCA 4 M HCl 50 363 1080 Li, Ni, Co, Al: About100
[68]
Mixed-type batteries
1M H2SO4 - 50 368 240 Li:93.40/Ni: 96.30 Co:66.20/Mn:50.2
[69]
5vol% H2O2
50 368 240 Li:93.40/Ni:96.30 Co:79.20/Mn:84.60
0.075M NaHSO3
20 368 240 Li:96.70/Ni: 96.40 Co:91.60/Mn:87.90
NCM311 1M H2SO4 1vol% H2O2
40 313 60 Li, Ni , Co, Mn: About 99.70
[70]
NCM311 2 M L-Tartaric acid
4vol% H2O2
17 343 30 Li: 99.70/Ni :99.31 Co:98.64/Mn:99.31
[71]
NCM311 2 M Formic acid
6vol% H2O2
50 333 10 Li:98.22/Ni:99.96 Co:99.96/Mn:99.95
[72]
NCM311 3 M Tricarbox-ylic acid
4vol% H2O2
50 333 30 Li: 99.70/Ni: 93.00 Co:91.80/Mn:89.80
[73]
LiNi1/3Co1/3Mn1/3O2
1.2 M DL-malic acid
1.5vol% H2O2
40 353 30 Li:98.90/Ni:95.10 Co:94.30/Mn:96.40
[74]
NCM 3.5 M Acetic acid
4vol% H2O2
40 333 60 Li: 99.97/Ni: 92.67 Co:93.62/Mn:96.32
[75]
Table 6 Leaching rate of metals from active material in spent LIBs with
biological bacteria [81-86]
Type of LIBs
Leaching reagents Decomposing acids Leaching rate/% Ref.
NCM batteries
Aspergilus niger (PTCC 5210)
gluconic, citric, malic and oxalic acid
Li:100/Ni:54/Co:64/Mn:77 [81]
Spent coin
A. thiooxidans (PTCC 1717)
H2SO4 Li: 99/Co: 60/Mn: 20 [82]
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cells Laptop batteries
A.thiooxidans, A.ferrooxidans
H2SO4 Li:99.20/Ni:89.4/Co:50.4 [83]
NCM batteries
Aspergilus niger gluconic, citric, malic and oxalic acid
Li:100/Ni:45/Co:38/Mn:72 [84]
NCM batteries
Aspergilus niger gluconic, citric, malic and oxalic acid
Li: 95/Ni:38/Co:45/Mn:70 [85]
NCM batteries
Sulfur-oxidizing bacteria (SOB) Iron-oxidizing bacteria (IOB)
Sulfur-A.t system, Pyrite-L.f system MS-MC system
NCM: >95 [86]
LiFePO4 Li: 98 LiMn2O4 Li: 95/Mn:96
Table 7 Summary of the chemical precipitation parameters investigated in the
literature [90]
Elements Precipitates Precipitants pH Ref. Li Li2CO3 Na2CO3 - 137, 157 and 187
LiF NH4F - 136 Li3PO4 H3PO4/Na3PO4 - 102, 159 and 188
Co Co(OH)2 NaOH 10 114 CoCO3 Na2CO3 9–
10 157 and 212
Co2O3·3H2O NaClO 3 182 CoC2O4·2H2O H2C2O4/(NH4)2C2O4 1.5,
2 136, 186 and 187
Ni Ni(OH)2 NaOH 8,11 114 and 182 NiCO3 Na2CO3 9 160 NiC8H14N4O4 C4H8N2O2 5,9 114 and 201
Mn Mn(OH)2 NaOH 12 114 MnCO3 Na2CO3 7.5 160 MnO2 KMnO4 2 114
Ni/Co/Mn co-precipitation
NixCoyMnz(OH)2 NaOH 11 73, 74 and 208 (NixCoyMnz)CO3 Na2CO3 7.5–
8 213
Fe/Al/Cu impurities Fe(OH)3 NaOH 3–6 113, 157, 186, 201 and 214
Al(OH)3 Cu(OH)2
Table 8 Regeneration preparation and electrochemical properties of cathode
materials from leaching solution [61,101-107]
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Regenerated NCM materials
NCM 333
NCM523 NCM 333
NCM 333
Li-riched NCM
Mg-doped NCM333
V2O5-coated NCM333
Al-doped NCM333
Resynthesis method High temperature solid-state method
Co- precipitation
Co-precipitation
Co-precipitation
Hydrothermal method
Co-precipitation
Solid-state reaction
Co-precipitation
Reagent - NaOH NaOH NH3·H2O
Na2CO3 Na2CO3
NH3·H2O - NH4VO3
Calcination temperature/k
723→1173 773→1123 1173 773→1173 723→1173 - 623
Initial charge capacity/(mAh·g-1)
201 198.4 178 198.9 About 330 175.4 - About 230
Initial discharge capacity/(mAh·g-1)
155.4 172.9 158 163.5 258.8 152.7 172.4 170
Cycles 30 50 100 50 50 50 100 50 Capacity retention /%
83.01 93.8 80 94.01 87 94 90.6 About 88
Rate performance: current density/(C) //Discharge capacity/(mAh·g-1) (approximation) Back to original current density
- 0.2C //180-170 0.5C //170-168 1C //162-161 2C //158-159 168-170
0.1C //149-150 0.2C //149-146 1/3C //131-138 0.5C //139-177 C //130-131 -
0.2C //156-154 0.5C //150-144 1C //139-135 2C //130-127 148-152
0.1C //245-262 0.2C //240-235 0.5C //220-200 1C //190-175 2C //160-150 230-222
- 0.1C //178-160 0.2C //175-173 0.5C //160-152 1C //135-131 2C //110-100 173-175
0.1C //165-147 0.2C //145-132 0.5C //134-120 1C //117-115 2C //107-98 132-155
Ref. [61] [101] [102] [103] [104] [105] [106] [107]
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<Figure captions>
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Fig. 1. Process flow of hydrometallurgical recovery method for waste NCM cathode materials.
Spent LiNixMnyCo1-x-yO2 barreries
Anode material、Shell and separator
Leaching residue
Leachate
Purification• Chemical precipitation• Ion exchange• Solvent extraction• Deep eutectic solvent (DESs)• Chemical precipitation• Evaporation
In NaCl solutionCryogenic freezingDischarge
Dismanlting
Cathode material
Anode material
Electrolyte
Sepa-rator
Shell
Manual dismantlc
Mechanical dismantlc
Pretreatment
Cathode electrode
Leaching
Adjusting solution composition
Nickel sourceManganese sourceCobalt source
Re-synthesis
Calcination
• Inorganic acid leaching• Organic acid leaching• Bioleaching• Mechanochemical
leaching
• Heat treatment• Solvent dissolution • Mechanical separation• Ultrasonic treatment• Alkali dissolving
Li source(LiOH/Li2CO3)
Regenerated NCM materials
Separation and extraction of
metals
Pure metal or metal compound
• Co-precipitation• Sol-gel• Hydrothermal method• High temperature
solid-state method
Direct regenerationof NCM materials
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Fig. 2 Separation methods for leaching metals from active materials.
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Fig. 3 Process of chemical precipitation for hydrometallurgical recycling NCM material
from spent LIBs.
Cathode powder
Roasted products
Planetary ball milling
Lignite
Cathode material of spent LIBs
Pretreatment
Reduction roasting
Water CO2
Carbonated water leaching
650℃,3h
300rpm1h
20% carbon dosage
Filtrate(LiHCO3) Residue
Evaporation
Li2CO3
Acid leaching
Filtrate(Ni,Co,Mn) Residue
Purification
Solvent extraction and evaporation
NiSO4 ·6H2O CoSO4 ·7H2O NiSO4 ·6H2O
100℃ 1.15 times H2SO4 T=2.5 h,T=55 °C,Liquid/solid=3.5 mL·g−1
NaOH
Flow rate=30mL·min-1
T=1 h, T=65 °C,Liquid/solid=10mL·g−1
Roasting-Leaching-Single Method Seperation System
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Fig. 4 Details and mechanism of recycle of previous metals in spent NCM cathode
materials by reduction roasting combined acid leaching: Backscattering SEM and EDS
mapping results of the cathode scrap after reduction roasting(a-i); Effect of CO2 flow
rate (k: L/S ratio 7.5 mL·g−1, t=2 h, T=25 °C); XRD and SEM of LiCO3 (l) and residue
(m) after the carbonation water leaching; The comparasion of leaching efficiency
between roasted cathode scrap and unroasted cathode scrap(n). (93)
Cathode scrap of LIBS
Leaching
Muffle furnace(In argon
atmosphere)
Reduction Roasting
Carbonated Water
Leaching
2LiHCO3(aq) → Li2CO3(s)+H2O(aq)+CO2(g)Selective
Separation of Li
Evaporation
Separation of Ni、Mn
and Co
Acid Leaching
2Ni+2H2SO4+O2 → 2NiSO4+2H2O
2Co+2H2SO4+O2 → 2CoSO4+2H2O
MnO+H2SO4+O2 → MnSO4+H2O
a b
d e
c
f
g h i
k l
m n
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Fig. 5 Metals recovery process from the leachate of spent lithium-ion batteries by
combined solvent extraction and selective chemical precipitation.
Leachate
Cathode material
Filtration
Chemical precipitation(pH=6,t=30min)
Leaching Citric acid、H2O2
HCl
NiCl2
Filter cake Filtrate
Precipitation (NH4)2C2O4
Filtration CoC2O4·2H2O
Solvent extraction
Mn-loaded organic phase
MnSO4
Solvent(Li)
Na3PO4 Precipitation
Li3PO4
FiltrationStrippingH2SO4
C4H8N2O2
Saponified D2EHPA
Acid Leaching- Combined Methods Seperation System
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Fig. 6 Regeneration flow of LiNi1/3Co1/3Mn1/3O2 cathode material from leaching liquid
by co-precipitation.
Co-extraction
Extract liquor
Feed liquor
Extract liquor Raffinate
Stripping Purification
Adjusting composition(Ni:Mn:Co=1:1:1)
HydroxideCo-precipitation
Organic phase
MnSO4
NiSO4
CoSO4
Carbonate precipitation
NaOHNa2CO3
Na2CO3
Ni1/3Co1/3Mn1/3(OH)2 Li2CO3
Solid state reaction
LiNi1/3Co1/3Mn1/3O2
Conventional Leaching-Regeneration System by Co-precipitation
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Fig. 7 Re-synthesis flow of LiNi1/3Co1/3Mn1/3O2 cathode material from leachate of
spent LIBs by sol-gel method.
Diamanlting
Spent LiNixMnyCo1-x-yO2 barreries
Steel Anode electrode
Basic solvent
Cathode electrode
Discharging
Drying
5% NaOH
Calcination
NaOH
Acid leaching Lactic acid、H2O2
Filtration
Adjusting composition(Ni:Mn:Co=1:1:1) Acetate
Sol-gel method
Calcination
LiNi1/3Co1/3Mn1/3O2
Leaching-Regeneration System By Sol-gel
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Fig. 8 Possible products and mechanism in the lactic acid leaching process (a); XRD
and SEM patterns of R-NCM and F-NCM samples(b); Electrochemical performances of
R-NCM and F-NCM samples: charge/discharge profiles at 0.2 C(c); cycling
performances at 1 C(d); rate performances at different currents(e); and Nyquist plots
in the frequency range of 100 kHz to 0.01 Hz(f). (108)
F-NCM
R-NCM
a
c d
e f
b
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Fig. 9 Diagram illustration of recycle and regeneration of NCM111cathode materials under
three different routes (a); SEM images of DC-600(b), SD-800(c)and BD-800(d) samples;
rate performances of DC(e) samples at 0.2 C; cycling performances of DC(f) samples. (109)
b
c
a
d
fe
Direct Regeneration Mechanism
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Fig. 10 The separation of cathode materials and Al foil from spent LIBs by using choline
chloride-glycerol DESs.
Choline Chloride+Glycerol(DES)
Manual diamanlting
Spent LiNixMnyCo1-x-yO2 barreries
Organic separators
Anode electrode
Cutting、Stripping
Cathode electrode
Discharging
Metal shell
Deep-eutectic solvent dissolution
5% NaOH
Manual separation
Al foil Cathode material
DESs pretreatment system