Search Results (475)

Recycling of lithium-ion batteries (LIBs) remains challenging due to high energy requirements, losses of key elements like lithium, and the heterogeneity of waste streams arising from different cathode chemistries. This study evaluates multiple recycling methods for LIBs black mass (BM), to recover critical raw materials and other valuable components. Three types of BM including nickel–manganese–cobalt (NMC), lithium iron phosphate (LFP) and a heterogeneous mixture of cell phones and laptops (HL; German: Handy/Laptops), were treated using froth flotation, pyrometallurgy, and biohydrometallurgy and their respective recovery efficiencies were assessed. The flotation results revealed that the HL sample had the lowest mis-recovery of non-ferrous metals into the froth product (around 10%), leading to further flotation only for HL. During screening, 94–99% of iron, phosphorus, and carbon in LFP-type BM were recovered in the fine fraction (<45 µm), while 92–99% of lithium, cobalt, manganese, nickel, and carbon in NMC-type BM were recovered in the same fraction. During precipitation, 99% of iron and 100% of phosphorus were recovered from LFP bioleachates at pH 3, while ~97–100% of dissolved cobalt, manganese, and nickel were recovered from NMC bioleachates. These findings confirm that no single recycling method is optimal for all battery chemistries. Full article

The booming clean energy industry has driven the expansion of photovoltaic (PV) and lithium-ion battery (LIB) sectors, causing the accumulation of new energy solid wastes such as wind turbine blades (WTB), PV modules and LIBs. Such solid wastes exhibit prominent characteristics such as multi-layer composition, a high degree of cross-linking, and multi-component coupling, presenting both high resource value and significant recycling challenges. This paper systematically reviews the material structural characteristics, EoL attributes, and current resource utilization status of these three new energy solid wastes. Existing recycling technologies are classified into three categories based on material structural evolution and value realization pathways: structure-retaining mechanical conversion, selective component extraction, and structure-reconstruction-based full-component upcycling. Furthermore, this study further compares various recycling routes in terms of recycling depth, value creation and development potential. The analysis indicates that, in the face of the impending large-scale retirement wave, relying solely on morphological reuse or partial component extraction is inadequate to meet the demands for efficient, high-value, and low-carbon recycling. Consequently, structure-reconstruction-based full-component upcycling will emerge as a crucial development direction for the resource utilization of new energy solid wastes. This paper provides a theoretical reference for related technological research and development, process optimization, and industrial system layout.: Full article

Reaching the end of their lifecycle, lithium-ion batteries contain significant amounts of lithium residues as well as valuable metals such as Co, Ni, and Mn, presenting both environmental risks and opportunities for resource recovery. Recent advances in hydrometallurgical, pyrometallurgical, and biotechnological methods enable the recovery of high-purity lithium compounds while also increasing their economic viability. This study analyzes the contribution of lithium recovery methods to sustainability criteria, their annual averages, and total data between 2008 and 2026, considering the number of academic references in the literature. The analysis compares the contributions of recycling methods to lithium and other metal recovery efficiency, process efficiency, energy consumption, environmental impact, economic impact, adaptation to technological developments, and integrated applications. LIB recycling methods showed higher overall and annual average sustainability contributions to the recovery efficiency of other metals and lithium compared to other criteria. Their contributions to process efficiency and the environment were also relatively high. However, their contributions to the economy, adaptation to technological developments, and integration of methods remain low. Furthermore, since the contribution to energy consumption is negative overall, further academic studies are needed to improve contributions, particularly in energy consumption and the other three criteria mentioned above. Full article

The rapid increase in electric vehicles has increased the generation of spent lithium-ion batteries (LIBs) and the need for efficient lithium recovery technologies. This study compared two distinct sulfation roasting routes, using sodium sulfate (Na₂SO₄) at 750 °C and sulfuric acid (H₂SO₄) at 550 °C, applied to black mass derived from lithium iron phosphate (LFP) and lithium nickel manganese cobalt oxide (NCM) batteries. Metal extraction efficiencies were determined by inductively coupled plasma optical emission spectrometry, while reaction products were identified by X-ray diffraction analysis. Sulfation roasting using Na₂SO₄ resulted in low lithium recovery for both materials, with maximum extractions of 5.7% for LFP and 24.5% for NCM. In contrast, H₂SO₄-assisted roasting achieved high lithium recovery from NCM black mass, reaching 90.8%, 91.5%, and 88.5% at 45, 90, and 180 min at 550 °C, respectively, with lithium predominantly converted into water-soluble lithium sulfate. Lithium extraction from LFP black mass remained below 13% under all conditions. Statistical analysis confirmed that lithium recovery at 45 min was equivalent to longer residence times, while prolonged roasting increased manganese coextraction and altered cobalt and nickel behavior. Overall, sulfuric acid-assisted sulfation roasting is an efficient and energy-favorable route for lithium recovery from NCM black mass, whereas sulfation roasting is unsuitable for LFP materials, under the tested conditions. The results highlight the importance of cathode chemistry segregation and demonstrate the feasibility of reducing processing time without compromising lithium recovery. Full article

With the increasing prevalence of lithium–ion batteries, the recycling of battery materials is becoming increasingly important. Functional recycling represents a promising approach in this context, one that is often based on aqueous treatment steps. This study examines the aqueous treatment of positive electrodes coated with various cathode active materials and their mixtures. To this end, the electrodes were leached in two different broad-range buffer systems in the pH range of 5 to 11. The investigations focused on the temporal evolution of the pH value, the time-dependent leaching of the active material components, and the dissolution of the aluminum current collector. The results show that process parameters, particularly the initial pH value, the treatment duration, and the composition of the process medium, influence both the leaching of the active materials and the corrosion of the aluminum current collector. Furthermore, the coated electrodes studied show significant differences in the stability of the active materials, which sometimes deviate from the properties of the respective pure active materials described in the literature, suggesting additional interactions within the electrode structure. The results highlight the need for targeted process optimization to create the conditions for the successful functional recycling of active materials from lithium–ion batteries. Full article

Second-life electric vehicle (EV) batteries are increasingly recognized as valuable resources for stationary energy storage. However, the heterogeneous degradation of retired batteries makes reliable and application-oriented reuse decisions challenging. Existing studies primarily focus on battery health estimation or degradation characterization, while limited attention has been given to systematically translating experimentally measured health indicators into practical second-life deployment decisions. To address this gap, this study proposes an experimental multi-metric battery health assessment and decision-support framework for application-oriented screening and reuse pathway allocation of retired EV batteries. A total of 91 s life lithium-ion battery cells were experimentally characterized through standardized laboratory charge–discharge testing. Multiple complementary health indicators, including State of Health (SoH), discharge capacity, round-trip energy efficiency, and voltage–current time-series characteristics, were extracted and statistically analyzed to evaluate residual battery performance and degradation behavior. The experimental results reveal substantial variability among retired batteries, with SoH values ranging from approximately 22% to 96%, while more than half of the tested cells exhibit SoH below 60%. Furthermore, batteries with comparable SoH frequently demonstrate different energy efficiencies, indicating that capacity retention alone is insufficient for reliable second-life battery assessment. Building upon these findings, a transparent rule-based decision-support framework is developed to map experimentally measured battery health indicators to application-oriented reuse pathways, including grid-support systems, residential energy storage, backup applications, and recycling. The proposed framework establishes a practical bridge between laboratory battery characterization and deployment-oriented second-life decision-making, providing an interpretable and experimentally grounded methodology for scalable battery screening and sustainable reuse planning. Full article

The accelerating transition toward renewable electricity generation has elevated grid-scale electrochemical energy storage from an ancillary grid service to a foundational infrastructure requirement. This review provides a comprehensive account of rechargeable battery technologies for stationary grid applications, spanning advanced lithium-ion systems, sodium-ion and post-lithium multivalent chemistries, vanadium and organic flow batteries, solid-state architectures, and high-energy-density future systems such as lithium-sulfur and metal-air cells. The techno-economic context of grid-scale storage is systematically examined, including performance metrics, market drivers, and regulatory frameworks. Each battery chemistry is analyzed with respect to electrochemical mechanism, cycle life, energy density, safety profile, material availability, and commercial readiness. Non-electrochemical storage technologies are discussed as system-level alternatives. Battery safety engineering, thermal management system design, thermal runaway mechanisms and prevention, and failure containment strategies are examined in depth, followed by analysis of critical material supply-chain vulnerabilities, life-cycle assessment, and recycling pathways. The expanding role of artificial intelligence, machine learning, and digital twin frameworks in optimizing performance and enabling predictive maintenance is reviewed. Key challenges, including material bottlenecks, manufacturing scalability, long-duration storage gaps, and the absence of harmonized performance standards, are identified, and the review concludes with a techno-economic roadmap toward cost-competitive, resilient, and low-carbon grid storage. Full article

Global growth in electric mobility, portable electronics, and renewable energy storage has increased concerns about the environmental and economic impacts of managing end-of-life lithium-ion and lead-acid batteries. Although these batteries support the transition to renewable energy, their disposal presents significant challenges. Recycling has emerged as a key strategy to reduce resource depletion, limit pollution, and recover valuable materials. This study systematically reviewed and quantitatively synthesised the literature published between 2000 and 2025, assessing the environmental impacts of battery recycling programs. The review followed PRISMA guidelines to ensure a transparent and rigorous study selection process. Data from peer-reviewed articles, industry reports, and policy documents were analysed, focusing on indicators such as greenhouse gas emissions, energy use, material recovery efficiency, and economic returns. Statistical methods, including Hedges’ g, heterogeneity testing, and sensitivity analysis within a random-effects model, were applied to account for variability across technologies and battery types. The results show that recycling generally lowers emissions and improves resource recovery compared to virgin material extraction, though performance varies. Lead-acid recycling demonstrates stronger environmental benefits due to mature technologies and established systems, while lithium-ion recycling shows positive but lower gains, limited by higher energy demands and less-developed processes. Overall, recycling is essential for reducing environmental impacts and supporting a circular economy, though lithium-ion systems require further technological and policy advancements. These findings can be used by governments to strengthen regulatory frameworks to support recycling industries and invest in advanced lithium-ion recycling technologies to improve efficiency. Despite the existing limitations, the benefits of recycling outweigh the drawbacks, making it a necessary strategy for sustainable battery waste management. Full article

The rapid expansion of lithium-ion battery (LIB) use in electric vehicles and large-scale energy storage systems has intensified the need for sustainable end-of-life management. While most research and industrial efforts have focused on recovering valuable metals, graphite anodes, despite constituting a significant portion of battery mass, remain relatively overlooked. This review evaluates current progress in graphite anode recycling, emphasizing technical challenges, scalability, and economic and geopolitical considerations. Conventional recycling methods, including hydrometallurgical, pyrometallurgical, and direct recycling processes, offer viable routes for material recovery but are often constrained by high energy demands, chemical consumption, and degradation of graphite quality. Regenerated graphite exhibits competitive electrochemical performance, with initial Coulombic efficiencies above 90% and reversible capacities comparable to those of commercial materials. In addition, strategies such as surface modification and defect engineering have proven effective in restoring structural integrity and enhancing cycling stability. Despite these advances, major challenges persist in achieving cost-effective, large-scale implementation and consistent material quality suitable for reuse in battery manufacturing. Given increasing supply risks and rapidly rising global demand for graphite, advancing sustainable recycling technologies has become essential. This review emphasizes the need for integrated technological innovation and supportive policy frameworks to enable the development of a circular economy for graphite. Full article

The application of a huge number of lithium-ion batteries (LIBs) to electric vehicles has produced much solid waste. If not disposed properly, the solid waste may cause environmental pollution and is, per se, a waste of resources. Therefore, recycling valuable metals from LIBs is considered an ideal option for preventing environmental pollution and alleviating waste. Taking sulfuric acid (H₂SO₄) as the leaching agent and glucose (C₆H₁₂O₆) as the reducing agent, the ultrasonic-assisted reducing leaching was used to recycle lithium (Li) and iron (Fe) from spent lithium iron phosphate (LFP) batteries. Based on experimental results of conventional leaching, the research aimed to examine the influence of ultrasonic treatment on leaching rates of Li and Fe. Results show that the leaching rates of Li and Fe are separately 96.53% and 96.8% when the concentration of H₂SO₄ is 2 mol/L, the concentration of C₆H₁₂O₆ is 2 mol/L, the liquid–solid ratio is 15 mL/g, leaching temperature is 70 °C, leaching time is 60 min, and ultrasonic power is 100 W. Compared with conventional leaching, the leaching rates of Li and Fe separately increase by 10.84% and 12.33% through ultrasonic-assisted leaching under the same experimental conditions. Kinetics analysis of ultrasonic-assisted reducing leaching indicates that the activation energies of Li and Fe are 10.84 kJ/mol and 16.24 kJ/mol, respectively. The ultrasonic-assisted reducing leaching process of Li and Fe from LFP batteries is controlled by diffusion. Full article

In recent years, owing to the extensive application of lithium-ion batteries (LIBs) in large-scale energy storage, transportation systems, and portable electronics, the LIB market has expanded rapidly. Proper recycling of spent LIBs can significantly alleviate environmental and economic burdens. Bioleaching, as an environmentally friendly and cost-effective approach for metal recovery from primary and secondary resources, is particularly suitable for the processing of spent LIBs. However, its efficiency significantly decreases under high-pulp-density conditions. Therefore, improving metal recovery performance under such conditions remains a critical challenge. This review systematically summarizes the microorganisms and leaching strategies employed for LIB bioleaching in the related peer-reviewed publications from 2015 to 2025, which were retrieved from the Web of Science, Scopus, and ScienceDirect databases. Based on this, this review analyzes the mechanistic limitations under high-pulp-density conditions and elucidates the key factors responsible for reduced efficiency. Furthermore, several process-intensification strategies are discussed, along with future perspectives for industrial-scale application. The increasing market demand and rapid technological development in LIB recycling highlight the strong potential of bioleaching technologies. This review provides mechanistic insights into microbial recovery processes and offers guidance for future research on high-pulp-density bioleaching systems. Full article

The rapid growth of electric mobility, renewable-energy storage, and portable electronics has sharply increased global lithium demand. Conventional lithium extraction methods, including hard-rock mining and brine evaporation, are land-intensive, slow, water-consumptive, and carbon-intensive. Adsorption has therefore received substantial attention for lithium recovery, due to its simple operation, cost-effectiveness, and facile scalability. In this regard, zeolite-based adsorbents have emerged as promising next-generation materials, mainly because of their crystalline frameworks, tunable pore architectures, ion-exchange functionality, and exceptional thermal and chemical stability. Existing reviews on adsorption-based lithium recovery have predominantly focused on polymeric materials, ion-exchange resins, and lithium-ion sieves (including lithium manganese oxide-based, titanium-based, and aluminum hydroxide-based adsorbents). To fill this gap, we present a dedicated and comprehensive review of zeolite-based adsorbents for sustainable lithium recovery from non-conventional lithium resources such as brines, geothermal fluids, seawaters, and battery-recycling leachates. By systematically and rigorously analyzing existing studies on this topic, we identify five guiding design principles: (i) zeolite framework charge density, (ii) zeolite framework topology and pore architecture (iii) morphology (size and shape), (iv) zeolite-based hybrid materials, and (v) operational design parameters (e.g., pH and temperature). Each design element is discussed in depth to clarify how lithium adsorption capacity and selectivity, transport behavior, and adsorption mechanisms can be controlled across diverse feedstocks. We further discuss the advantages, limitations, and future research needs for zeolite-based lithium capture. To the best of our knowledge, this is the first review centered on zeolite-based materials for lithium recovery. The knowledge and insights provided here aim to drive researchers into advancing zeolite-based adsorbents toward sustainable, next-generation lithium recovery technologies. Full article

The recycling of spent lithium-ion batteries and selected complex electronic waste fractions is commonly evaluated using isolated metrics such as leaching yield, metal removal efficiency, and reagent consumption. However, this approach fails to address the central challenge of sustainable valorization: integrating upstream conversion with downstream selective recovery without shifting environmental and separation burdens. This review focuses specifically on spent LIBs as the primary model system, while also drawing insights from related e-waste streams (e.g., printed circuit boards and polymer-containing residues) where the interface-driven framework applies. It examines how key interfaces—solid–fluid, polymer–metal–fluid, membrane–solution, electrode–electrolyte, and crystal–solution—govern metal mobilization, selectivity, effluent quality, product purity, and scalability. Emphasis is placed on hydrothermal and supercritical water processing, PVC/CPVC (Polyvinyl Chloride/Chlorinated Polyvinyl Chloride)-assisted metal mobilization and membrane-based recovery techniques, including nanofiltration, membrane distillation, membrane distillation crystallization, ion exchange, and electrochemical methods. Supercritical water and membrane processes are complementary only when upstream chemistry is designed to facilitate downstream separation. PVC-rich waste is reconsidered as a reactive chlorine source, provided that corrosion, HCl formation, and salt precipitation are controlled. Critical gaps include incomplete mass balances, limited multicomponent studies, weak integration between process stages, and scarce techno-economic and life-cycle analyses. A roadmap is proposed for scalable, integrated hydrothermal–membrane systems enabling efficient resource recovery and water reuse. Full article

The increasing demand for lithium-ion batteries (LIBs) raises concerns about the security of critical raw material supply and the management of hazardous waste. Efficient recycling can alleviate these issues by transforming spent batteries into high-value secondary materials for the circular economy. Industrial recycling has traditionally focused on the recovery of nickel (Ni) and cobalt (Co), whereas lithium (Li) recovery has often been sidelined due to technical complexities and fluctuating economic incentives. To meet the European Union (EU) Batteries Regulation target of 80% lithium recovery by the end of 2031, technically effective and economically viable lithium recovery strategies are required. This study investigates the use of food-grade sucrose as an organic reductant for the targeted recovery of lithium from NMC622 and NCA battery materials. The process combines sucrose-assisted reductive roasting with selective water leaching. The effects of roasting temperature, holding time, sucrose dosage, and heating rate were systematically evaluated and optimised. Under the best conditions of 600 °C, 15 min, 15 wt% sucrose, and a heating rate of 20 °C/min, lithium leaching efficiencies of 93.2% and 87.6% were achieved for separated NMC622 cathode material and NMC622-derived black mass, respectively. The method was also applicable to NCA-based black mass, reaching 83.7% lithium recovery under the same conditions. Mechanistic analysis revealed that lithium release was strongly controlled by the extent of transition metal reduction. Cobalt was fully reduced to its metallic state under all tested conditions. However, maximum lithium recovery required nickel to be reduced to metallic Ni and manganese-containing phases to be converted to MnO. The sucrose-assisted roasting process was rapid and holding times longer than 15 min decreased lithium recovery. This decrease was caused by the formation of poorly soluble lithium-containing phases, such as LiF and Li₃PO₄. F composition analysis showed the black mass (1.06 wt%) and anode fractions (2.26 wt%) to contain significantly more F than the cathode fraction (0.46 wt%), hence leading to the 5% Li leaching efficiency difference between cathode and black mass fractions under most conditions tested. Overall, these results demonstrate that sucrose-assisted reductive roasting, followed by selective water leaching, provides a rapid and effective route for high-efficiency lithium recovery from NMC- and NCA-based battery materials. Full article

Lithium has become one of the key raw materials for the energy transition due to the central role of lithium-ion batteries in electromobility, energy storage, and the integration of renewable energy sources. However, the rapid increase in demand reveals growing environmental, social, geopolitical, and market tensions. The aim of the paper is a critical synthesis of global lithium utilization from the perspective of challenges, technological innovations, and integrative strategies supporting a more sustainable material-energy system. A broad, systematic literature review covering the entire value chain was applied: resources, extraction, processing, end-use applications, second life of batteries, recycling, and governance. The analysis shows that the strategic importance of lithium arises from the increasing demand pressure from electric vehicles and stationary storage, while the sustainability of the current model is constrained by supply concentration, uneven control over downstream stages, the water-carbon footprint of extraction and processing, social conflicts, and incomplete integration of secondary loops. At the same time, innovations such as direct lithium extraction (DLE), recovery from geothermal brines, design for recycling, second life, and battery passports can partially alleviate these tensions, but they do not eliminate the need for primary supply in the short term. The conclusion of the work is that sustainable global lithium utilization requires simultaneous diversification of sources, development of circular value chains, and multi-level governance integrating resource security, environmental efficiency, and social legitimacy. Full article