Search Results (203)

The literature clearly indicates that both academia and industry are strongly committed to developing comprehensive processes for spent Li-ion battery (LIB) recycling. In this regard, the current study presents an original contribution by providing a quantitative assessment of a large-scale recycling plant designed for the treatment of completely spent LIBs. In addition to a concept of the basic process, this assessment also considers a case study of a thermal integration and CO₂ capture subsystem. Process flow modeling software was used to evaluate the contribution of all process steps and equipment to overall energy consumption and to mass balance the data required for the technical assessment of the large-scale recycling plant. To underline the advantages and identify the optimal novel process concept, several key performance indicators were determined, such as recovery efficiency, specific energy/material consumption, and specific CO₂ emissions. In addition, the economic potential of the recycling plants was evaluated for the defined case studies based on capital and O&M costs. The results indicate that, even with CO₂ capture applied, the thermally integrated process with the combustion of hydrogen produced in the recycling plant remains the most promising large-scale configuration for spent LIB recycling. Full article

There is an increasing demand for the development of efficient and sustainable battery recycling processes. Currently, many recycling processes rely on toxic inorganic acids to recover materials from high-value battery chemistries such as lithium nickel manganese cobalt oxides (NMCs) and lithium cobalt oxide (LCOs). However, as cell manufacturers seek more cost-effective battery chemistries, the value of the spent battery value chain is increasingly diluted by chemistries such as lithium iron phosphate (LFPs). These cheaper alternatives present a difficulty when recycling, as current recycling processes are geared towards dealing with high-value chemistries; thus, the current processes become less economical. To date, much research is focused on treating a single battery chemistry; however, often, the feed material entering a battery recycling facility is contaminated with other battery chemistries, e.g., LFP feed contaminated with NMC, LCO, or LMOs. This research aims to selectively leach various battery chemistries out of a mixed feed material with the aid of a green organic acid, namely oxalic acid. When operating at the optimal conditions (2% solids, 0.25 M oxalic acid, natural pH around 1.15, 25 °C, 60 min), this research has proven that oxalic acid can be used to selectively dissolve 95.58% and 93.57% of Li and P, respectively, from a mixed LFP-NMC mixed feed, all while only extracting 12.83% of Fe and 8.43% of Mn, with no Co and Ni being detected in solution. Along with the high degree of selectivity, this research has also demonstrated, through varying the pH, that the selectivity of the leaching system can be altered. It was determined that at pH 0.5 the system dissolved both the NMC and LFP chemistries; at a pH of 1.15, the LFP chemistry (Li and P) was selectively targeted. Finally, at a pH of 4, the NMC chemistry (Ni, Co and Mn) was selectively dissolved. Full article

Electric passenger vehicles are set to dominate the European car market, driven by EU climate policies and the 2035 ban on internal combustion engine production. This study assesses the sustainability of this transition, focusing on global warming potential and Critical Raw Material (CRM) extraction throughout its life cycle. The intensive use of CRMs raises environmental, economic, social, and geopolitical concerns. These materials are scarce and are concentrated in a few politically sensitive regions, leaving the EU highly dependent on external suppliers. The extraction, transport, and refining of CRMs and battery production are high-emission processes that contribute to climate change and pose risks to ecosystems and human health. A Life Cycle Assessment (LCA) was conducted, using OpenLCA software and the Ecoinvent 3.10 database, comparing a Peugeot 308 in its diesel and electric versions. This study adopts a cradle-to-grave approach, analyzing three phases: production, utilization, and end-of-life treatment. Key indicators included Global Warming Potential (GWP100) and Abiotic Resource Depletion Potential (ADP) to assess CO₂ emissions and mineral resource consumption. Technological advancements could mitigate mineral depletion concerns. Li-ion battery recycling is still underdeveloped, but has high recovery potential, with the sector expected to expand significantly. Moreover, repurposing used Li-ion batteries for stationary energy storage in renewable energy systems can extend their lifespan by over a decade, decreasing the demand for new batteries. Such innovations underscore the potential for a more sustainable electric vehicle industry. Full article

The rising demand for sustainable energy storage has fueled the development of green batteries as alternatives to conventional systems. However, a major research gap lies in the unified integration of environmentally friendly materials and processes across all battery components—electrodes, electrolytes, and separators—without compromising performance or scalability. This review addresses this gap by highlighting recent advances in eco-conscious battery technologies, focusing on green electrode fabrication using water-based methods, electrophoretic deposition, solvent-free dry-press coating, 3D printing, and biomass-derived materials. It also examines the shift toward safer electrolytes, including ionic liquids, deep eutectic solvents, water-based systems, and solid biopolymer matrices, which improve both environmental compatibility and safety. Additionally, biodegradable separators made from natural polymers such as cellulose and chitosan offer enhanced thermal stability and ecological benefits. The review emphasizes the importance of lifecycle considerations like recyclability and biodegradability, aligning battery design with circular economy principles. While significant progress has been made, challenges such as standardization, long-term stability, and industrial scalability remain. By identifying key strategies and future directions, this article contributes to the foundation for next-generation green batteries, promoting their adoption in environmentally sensitive applications ranging from wearable electronics to grid storage. Full article

The conventional spent lithium-ion batteries (LIBs) recycling method suffers from complex processes and excessive chemical consumption. Hence, this study proposes an electrochemical strategy for achieving reductant-free leaching of high-valence transition metals and efficient separation of valuable components from spent cathode sheets (CSs). An innovatively designed sandwich-structured electrochemical reactor achieved efficient reductive dissolution of cathode materials (CMs) while maintaining the structural integrity of aluminum (Al) foils in a dilute sulfuric acid system. Optimized current enabled leaching efficiencies exceeding 93% for lithium (Li), cobalt (Co), manganese (Mn), and nickel (Ni), with 88% metallic Al foil recovery via cathodic protection. Multi-scale characterization systematically elucidated metal valence evolution and interfacial reaction mechanisms, validating the technology’s tripartite innovation: simultaneous high metal extraction efficiency, high value-added Al foil recovery, and organic removal through single-step electrochemical treatment. The process synergized the dissolution of CM particles and hydrogen bubble-induced physical liberation to achieve clean separation of polyvinylidene difluoride (PVDF) and carbon black (CB) layers from Al foil substrates. This method eliminates crushing pretreatment, high-temperature reduction, and any other reductant consumption, establishing an environmentally friendly and efficient method of comprehensive recycling of battery materials. Full article

This review contains a compilation of data about the occurrence, mining, refining, and biological actions of lithium, without claiming completeness of knowledge. This should give a baseline for judging future pollutions of environmental and agricultural items and human nutrition and may show still existing gaps of screening. Emerging electromobility and use of computers leads to a steep increase in Li-based batteries, which are a source of hazardous waste unless recycled. Lack of recovery methods from effluents and sewage, however, will increase pollution with soluble Li-salts from increasing mining and waste in the future; therefore, biochemical effects of levels out of ambient range have been included. Many published data are hidden in multi-element tables, including the data of the author. Mobile fractions of soils and soil-to-plant transfer, as well as retainment in animal tissues, are low. A lot of data, starting from geology via soils, plants, water, and human nutrition, lead to a largely unknown average daily intake for men. With respect to nutrition of dairy cows, the contribution of Li from water was highest among all elements investigated, but only 4% of intake. Main sources for human nutrition are mineral water and table salt. Li is not labelled on mineral water bottles, nor table salt, which are the main sources. Though some data have been gathered, for human nutrition, the average daily intake is uncertain to estimate because some mineral waters are quite high in Li. Full article

The increasing need-based demand for lithium iron phosphate (LFP) batteries in electric vehicles and energy storage systems necessitates the development of efficient and sustainable recycling methods. This study investigates the effect of oxidative roasting on lithium extraction from industrially sourced LiFePO₄ (LFP) blackmass containing high graphite content (~46%) and mixed electrode materials. Roasting at 650 °C for one hour converted LiFePO₄ into water-soluble Li₃Fe₂(PO₄)₃ and Fe₂O₃, while reducing carbon and fluorine levels. However, contrary to expectations, mild-acid leaching (pH 2, 40 g/L, 20 °C) of roasted blackmass did not improve lithium recovery compared to unroasted material, yielding approximately 33% extraction efficiency. Strong-acid leaching (pH 0, H₂SO₄/H₂O₂) achieved over 95% lithium recovery but also resulted in significant co-dissolution of iron and other impurities. Our XRD and SEM analyses showed that some lithium-containing phases remained in the residue after water leaching, while acid leaching left mainly iron oxide and graphite. These results suggest that, for complex and graphite-rich industrial blackmass, roasting may not always deliver the expected boost in lithium recovery. Our findings highlight the need to tailor recycling processes to the specific characteristics of battery waste and suggest that direct hydrometallurgical methods could be more effective for complex, impurity-rich LFP blackmass streams. Full article

Pyrometallurgical recycling of lithium-ion batteries presents distinct advantages including streamlined processing, simplified pretreatment requirements, and high throughput capacity. However, its industrial implementation faces challenges associated with high energy demands and lithium loss into slag phases. This investigation develops an integrated reduction smelting–chloridizing volatilization process for the comprehensive recovery of strategic metals (Li, Mn, Cu, Co, Ni) from spent ternary lithium-ion batteries; calcium chloride was selected as the chlorinating agent for this purpose. Thermodynamic analysis was performed to understand the phase evolution during reduction smelting and to design an appropriate slag composition. Preliminary experiments compared carbon and aluminum powder as reducing agents to identify optimal operational parameters: a smelting temperature of 1450 °C, 2.5 times theoretical CaCl₂ dosage, and duration of 120 min. The process achieved effective element partitioning with lithium and manganese volatilizing as chloride species, while transition metals (Cu, Ni, Co) were concentrated into an alloy phase. Process validation in an induction furnace with N₂-O₂ top blowing demonstrated enhanced recovery efficiency through optimized oxygen supplementation (four times the theoretical oxygen requirement). The recovery rates of Li, Mn, Cu, Co, and Ni reached 94.1%, 93.5%, 97.6%, 94.4%, and 96.4%, respectively. This synergistic approach establishes an energy-efficient pathway for simultaneous multi-metal recovery, demonstrating industrial viability for large-scale lithium-ion battery recycling through minimized processing steps and maximized resource utilization. Full article

Batteries are used as energy storage devices in various equipment. Today, research is focused on solid-state batteries (SSBs), replacing the liquid electrolyte with a solid separator. The solid separators provide electrolyte stability, no leakage, and provide mechanical strength to the battery. Separators are mostly manufactured by either traditional processes or 3D printing technologies. These processes involve making a slurry of plastic, active and conductive material and usually adding a plasticizer when making thin films or filaments for 3D printing. This study investigates the additive manufacturing of solid-state electrolytes (SSEs) by employing fused deposition modeling (FDM) with recyclable, bio-derived polylactic acid (PLA) filaments. Precise control of macro-porosity is achieved by systematically varying key process parameters, including raster orientation, infill percentage, and interlayer adhesion conditions, thereby enabling the formation of tunable, interconnected pore networks within the polymer matrix. Following 3D printing, these engineered porous frameworks are infiltrated with lithium hexafluorophosphate (LiPF₆), which functions as the active ionic conductor. A tailored thermal sintering protocol is then applied to promote solid-phase fusion of the embedded salt throughout the macro-porous PLA scaffold, resulting in a mechanically robust and ionically conductive composite separator. The electrochemical ionic conductivity and structural integrity of the sintered SSEs are characterized through electrochemical impedance spectroscopy (EIS) and standardized mechanical testing to assess their suitability for integration into advanced solid-state battery architectures. The solid-state separator achieved an average ionic conductivity of 2.529 × 10⁻⁵ S·cm⁻¹. The integrated FDM-sintering process enhances ion exchange at the electrode–electrolyte interface, minimizes material waste, and supports cost-efficient, fully recyclable component fabrication. Full article

In the wake of global energy transition and the “dual-carbon” goal, the rapid growth of electric vehicles has posed challenges for large-scale lithium-ion battery decommissioning. Retired batteries exhibit dual attributes of strategic resources (cobalt/lithium concentrations several times higher than natural ores) and environmental risks (heavy metal pollution, electrolyte toxicity). This paper systematically reviews pyrometallurgical and hydrometallurgical recovery technologies, identifying bottlenecks: high energy/lithium loss in pyrometallurgy, and corrosion/cost/solvent regeneration issues in hydrometallurgy. To address these, an integrated recycling process is proposed: low-temperature physical separation (liquid nitrogen embrittlement grinding + froth flotation) for cathode–anode separation, mild roasting to convert lithium into water-soluble compounds for efficient metal oxide separation, stepwise alkaline precipitation for high-purity lithium salts, and co-precipitation synthesis of spherical hydroxide precursors followed by segmented sintering to regenerate LiNi_1/3Co_1/3Mn_1/3O₂ cathodes with morphology/electrochemical performance comparable to virgin materials. This low-temperature, precision-controlled methodology effectively addresses the energy-intensive, pollutive, and inefficient limitations inherent in conventional recycling processes. By offering an engineered solution for sustainable large-scale recycling and high-value regeneration of spent ternary lithium ion batteries (LIBs), this approach proves pivotal in advancing circular economy development within the renewable energy sector. Full article

This study investigates the optimization of an ammonia-based leaching process for the recovery of lithium and cobalt from spent LiCoO₂ cathodes, coupled with an energy-efficient ammonia stripping approach. Kinetic analysis revealed that both lithium and cobalt extraction follow pseudo-first-order kinetics, with activation energies of 76.54 kJ/mol and 97.22 kJ/mol, respectively, indicating a chemically controlled process. Optimal leaching conditions were established at 6 M NH₃, 1.5 M (NH₄)₂CO₃, liquid-to-solid ratio of 10:1, and 70 °C for 5 h, achieving 82.5% lithium and 96.1% cobalt recovery. The ammonia stripping process was optimized for energy efficiency, with operations at 95–98 °C providing the best balance between rapid NH₃ removal and energy consumption. At 98 °C, energy demand was reduced to ~282 kJ/mol, a sevenfold improvement over lower temperature operations. A stepwise separation strategy was developed, involving selective lithium precipitation at pH 10.7–10.8, followed by controlled ammonia stripping to precipitate cobalt at pH 8.8–9.0. This integrated approach offers a promising alternative to conventional acid-based recycling methods, combining high metal recovery with improved energy efficiency and reagent recyclability. Full article

Next-generation recycling technologies must be urgently innovated to tackle huge volumes of spent batteries, photovoltaic panels or printed circuit boards (WPCBs). Current e-waste recycling industrial technology is dominated by traditional recycling technologies. Herein, ionic liquids (ILs), deep eutectic solvents (DESs) and promising oxidizing additives that can overcome some traditional recycling methods of metal ions from e-waste, used in our works from last year, are presented. The unique chemical environments of ILs and DESs, with the application of low-temperature extraction procedures, are important environmental aspects known as “Green Methods”. A closed-loop system for recycling zinc and manganese from the “black mass” (BM) of waste, Zn-MnO₂ batteries, is presented. The leaching process achieves a high efficiency and distribution ratio using the composition of two solvents (Cyanex 272 + diethyl phosphite (DPh)) for Zn(II) extraction. High extraction efficiency with 100% zinc and manganese recovery is also achieved using DESs (cholinum chloride/lactic acid, 1:2, DES 1, and cholinum chloride/malonic acid, 1:1, DES 2). New, greener recycling approaches to metal extraction from the BM of spent Li-ion batteries are presented with ILs ([N_8,8,8,1][Cl], (Aliquat 336), [P_6,6,6,14][Cl], [P_6,6,6,14][SCN] and [Benzet][TCM]) eight DESs, Cyanex 272 and D2EHPA. A high extraction efficiency of Li(I) (41–92 wt%) and Ni(II) (37–52 wt%) using (Cyanex 272 + DPh) is obtained. The recovery of Ni(II) and Cd(II) from the BM of spent Ni-Cd batteries is also demonstrated. The extraction efficiency of DES 1 and DES 2, contrary to ILs ([P_6,6,6,14][Cl] and [P_6,6,6,14][SCN]), is at the level of 30 wt% for Ni(II) and 100 wt% for Cd(II). In this mini-review, the option to use ILs, DESs and Cyanex 272 for the recovery of valuable metals from end-of-life WPCBs is presented. Next-generation recycling technologies, in contrast to the extraction of metals from acidic leachate preceded by thermal pre-treatment or from solid material only after thermal pre-treatment, have been developed with ILs and DESs using the ABS method, as well as Cyanex 272 (only after the thermal pre-treatment of WPCBs), with a process efficiency of 60–100 wt%. In this process, four new ILs are used: didecyldimethylammonium propionate, [N_10,10,1,1][C₂H₅COO], didecylmethylammonium hydrogen sulphate, [N_10,10,1,H][HSO₄], didecyldimethylammonium dihydrogen phosphate, [N_10,10,1,1][H₂PO₄], and tetrabutylphosphonium dihydrogen phosphate, [P_4,4,4,4][H₂PO₄]. The extraction of Cu(II), Ag(I) and other metals such as Al(III), Fe(II) and Zn(II) from solid WPCBs is demonstrated. Various additives are used during the extraction processes. The Analyst 800 atomic absorption spectrometer (FAAS) is used for the determination of metal content in the solid BM. The ICP-OES method is used for metal analysis. The obtained results describe the possible application of ILs and DESs as environmental media for upcycling spent electronic wastes. Full article

Objective: The rapid growth of electric vehicle (EV) adoption has led to an unprecedented increase in lithium-ion battery (LIB) demand and end-of-life waste, underscoring the urgent need for effective recycling strategies. This review evaluates current progress in EV battery recycling and explores future prospects. Design: Review based on PRISMA 2020. Data sources: Scientific publications indexed in major databases such as Scopus, Web of Science, and ScienceDirect were searched for relevant studies published between 2020 and 15 April 2025. Inclusion criteria: Studies were included if they were published in English between 2020 and 15 April 2025, and focused on the recycling of electric vehicle batteries. Eligible studies specifically addressed (i) recycling methods, technologies, and material recovery processes for EV batteries; (ii) the impact of recycled battery systems on power generation processes and grid stability; and (iii) assessments of materials used in battery manufacturing, including efficiency and recyclability. Review articles and meta-analyses were excluded to ensure the inclusion of only original research data. Data extraction: Data were independently screened and extracted by two researchers and analyzed for recovery rates, environmental impact, and system-level energy contributions. One researcher independently screened all articles and extracted relevant data. A second researcher validated the accuracy of extracted data. The data were then organized and analyzed based on reported quantitative and qualitative indicators related to recycling methods, material recovery rates, environmental impact, and system-level energy benefits. Results: A total of 23 studies were included. Significant progress has been made in hydrometallurgical and direct recycling processes, with recovery rates of critical metals (Li, Co, Ni) improving. Second-life battery applications also show promise for grid stabilization and renewable energy storage. Furthermore, recycled batteries show potential in stabilizing power grids through second-life applications in BESS. Conclusion: EV battery recycling is a vital strategy for addressing raw material scarcity, minimizing environmental harm, and supporting energy resilience. However, challenges persist in policy harmonization, technology scaling, and economic viability. Future progress will depend on integrated efforts across sectors and regions to build a circular battery economy. Full article

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

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