Search Results (10)

With the increasing adoption of lithium-ion batteries (LIBs) as the batteries of choice in electromobility, personal electronic devices, and so on, comes the challenge of ageing, which prevents the batteries from performing optimally and meeting the design intent. This is observed in the form of declining power capability due to the increase in resistance and the reduction in capacity that can be stored or discharged from them. Unfortunately, the cost of assessing batteries after the first use remains a daunting challenge. In our work, we propose an approach that carries out fast preliminary grading based on resistance and capacity by first connecting old cells of the same chemistry and model in series with resistors to limit the branch current, then connecting the branches in parallel to equalise the voltages. A Simulink model of NCR18650PF Panasonic cells with adaptive-series resistance is compared with a fixed-series resistance and found to improve the balancing time from over 24 h to just 8 h. Electrochemical impedance spectroscopy (EIS) was carried out on the individual balanced cells between 0.1 Hz and 5 kHz so that the real impedance, imaginary impedance, absolute impedance, and phase were compared with the SOH of the cells at each frequency. Results show that the imaginary impedance in the 6.6 Hz frequency range shows a good correlation coefficient > 0.98 with the SOH, especially with a state of charge (SOC) of about 75–85% for the LCO cells. By selecting only a sample from all the cells that covers a wide range of ages and carrying out a full-capacity checkup on them, a simple correlation with the SOH and the EIS measurements for different frequencies can be used to estimate the SOH of the other cells that were connected in the same parallel connection. This is a considerable time saving in the charge and discharge time on the other cells in facilities that lack the capacity for simultaneous cycling of all cells. There are also huge energy savings in not having to cycle all the cells. Therefore, it offers a more efficient approach to grading spent cells than carrying out full capacity tests. 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

The electrode materials from spent lithium-ion batteries consist of graphite and lithium cobalt oxides (LCO), which cannot be efficiently separated by the conventional flotation technique due to the fine size distributions of graphite and LCO. In this work, nanobubbles were introduced to the flotation system of electrode materials. Nanobubbles were produced with the method of temperature difference. Different degrees of gas oversaturation in the water/slurry were achieved by raising the temperature of cold water (stored at 4 °C for at least 72 h) to target values of 20 °C, 25 °C, and 30 °C. It was found that the height and lateral distance of nanobubbles increased with the degree of gas oversaturation of water. In addition, the larger graphite agglomerations were observed to form in the presence of nanobubbles. The D₅₀ (chord length) of graphite agglomerations increased by 8 μm, 11 μm, and 21 μm, respectively, compared with the D₅₀ of graphite in natural water. More graphite agglomerations adhered to a captive bubble with the aid of nanobubbles than in the case of no nanobubbles, which was indicated by increased wrapping angles of graphite (agglomerations) adhering to a captive bubble. Furthermore, the maximum adhesion force between a captive bubble and substrate increases to 220, 270, and 300 μN as cold water temperature increases to 20, 25, and 30 °C, respectively. The frost of nanobubbles on a graphite surface and the resulting graphite agglomerations through the bridging effect of nanobubbles are thought to be responsible for the improved flotation performance of electrode materials. The present results indicate that the flotation performance of fine minerals can be regulated by regulating the gas oversaturation degree of the slurry. Full article

Recovering valuable metals from spent lithium-ion batteries (LIBs), a kind of solid waste with high pollution and high-value potential, is very important. In recent years, the extraction of valuable metals from the cathodes of spent LIBs and cathode regeneration technology are still rapidly developing (such as flash Joule heating technology to regenerate cathodes). This review summarized the studies published in the recent ten years to catch the rapid pace of development in this field. The development, structure, and working principle of LIBs were firstly introduced. Subsequently, the recent developments in mechanisms and processes of pyrometallurgy and hydrometallurgy for extracting valuable metals and cathode regeneration were summarized. The commonly used processes, products, and efficiencies for the recycling of nickel–cobalt–manganese cathodes (NCM/LCO/LMO/NCA) and lithium iron phosphate (LFP) cathodes were analyzed and compared. Compared with pyrometallurgy and hydrometallurgy, the regeneration method was a method with a higher resource utilization rate, which has more industrial application prospects. Finally, this paper pointed out the shortcomings of the current research and put forward some suggestions for the recovery and reuse of spent lithium-ion battery cathodes in the future. Full article

The literature indicates that utilizing pyrometallurgical methods for processing spent LiCoO₂ (LCO) batteries can lead to cobalt recovery in the forms of Co₃O₄, CoO, and Co, while lithium can be retrieved as Li₂O or Li₂CO₃. However, the technology’s high energy consumption has also been noted as a challenge in this recovery process. Recently, an innovative and sustainable approach using microwave (MW) radiation has been proposed as an alternative to traditional pyrometallurgical methods for treating used lithium-ion batteries (LiBs). This method aims to address the shortcomings of the conventional approach. In this study, the treatment of the black mass (BM) from spent LCO batteries is explored for the first time using MW–materials interaction under an air atmosphere. The research reveals that the process can trigger carbothermic reactions. However, MW makes the BM so reactive that it causes rapid heating of the sample in a few minutes, also posing a fire risk. This paper presents and discusses the benefits and potential hazards associated with this novel technology for the recovery of spent LCO batteries and gives information about real samples of BM. The work opens the possibility of using a microwave for raw material recovery in spent LIBs, allowing to obtain rapid and more efficient reactions. Full article

Research on the regeneration of cathode materials of spent lithium-ion batteries for resource reclamation and environmental protection is attracting more and more attention today. However, the majority of studies on recycling lithium-ion batteries (LIBs) placed the emphasis only on recovering target metals, such as Co, Ni, and Li, from the cathode materials, or how to recycle spent LIBs by conventional means. Effective reclamation strategies (e.g., pyrometallurgical technologies, hydrometallurgy techniques, and biological strategies) have been used in research on recycling used LIBs. Nevertheless, none of the existing reviews of regenerating cathode materials from waste LIBs elucidated the strategies to regenerate lithium nickel manganese cobalt oxide (NCM or LiNi_xCo_yMn_zO₂) cathode materials directly from spent LIBs containing other than NCM cathodes but, at the same time, frequently used commercial cathode materials such as LiCoO₂ (LCO), LiFePO₄ (LFP), LiMn₂O₄ (LMO), etc. or from spent mixed cathode materials. This review showcases the strategies and techniques for regenerating LiNi_xCo_yMn_zO₂ cathode active materials directly from some commonly used and different types of mixed-cathode materials. The article summarizes the various technologies and processes of regenerating LiNi_xCo_yMn_zO₂ cathode active materials directly from some individual cathode materials and the mixed-cathode scraps of spent LIBs without their preliminary separation. In the meantime, the economic benefits and diverse synthetic routes of regenerating LiNi_xCo_yMn_zO₂ cathode materials reported in the literature are analyzed systematically. This minireview can lay guidance and a theoretical basis for restoring LiNi_xCo_yMn_zO₂ cathode materials. Full article

The dissolution of LiCoO₂ (LCO) from spent lithium-ion batteries (LIBs) has been widely studied with organic and inorganic acids. Among these acids, HCl is the one that showed the best results when used at concentrations higher than 4 M. However, its higher cost compared with other acids is disadvantageous. Taking this into account, this work aims to perform a comparative study of the effect of different operational variables such as temperature, reaction time, leaching agent concentration (HCl) and reducing agent concentration (H₂O₂) on the dissolution efficiency of LCO for the systems HCl and HCl-H₂O₂ to determine the optimal parameters to achieve a maximum dissolution in minimum time at low temperatures and reagent concentrations. Increasing temperature, time and concentration of the reagents had a positive effect on the dissolution of LCO. When working with HCl 1.8 M, the highest dissolution for LCO, 91.0% was obtained at 348 K for 60 min. Furthermore, a slightly higher oxide dissolution (93.0%) was obtained in a reducing medium at the same temperature in half the time and with a concentration of HCl more than ten times lower. This will allow us to propose an alternative process to the existing ones with economic and ecological advantages. Full article

In the present manuscript, a simple hydrometallurgy process for recovering and recycling cobalt from spent lithium cobalt oxide LiCoO₂ (LCO) in lithium-ion batteries (LIBs) is described. First, the black material (BM) containing LCO active material is extracted by discharging, dismantling and detachment of cathode active materials with an organic solvent. Then, sulfuric acid (H₂SO₄) and hydrogen peroxide (H₂O₂) are used to fully dissolve Co and Li in an aqueous solution at high dissolution efficiency (more than 99% of Li and Co). After a purification step, Co is selectively precipitated and separated from Li, as CoCO₃, using a simple method. Results show that the obtained CoCO₃ crystals have a unique sheets-like structure with a purity of more than 97% and could be reused to regenerate LCO active material for LIB. The as-prepared sheet-like CoCO₃ was then converted to flower-like LCO through a solid-state reaction with commercial lithium carbonate (Li₂CO₃). Electrochemical performances of the regenerated LCO (LCO_Reg) in LIB have been studied. Interestingly, the flower-like LCO_Reg showed a good charge capacity of about 145 mAh.g⁻¹ at the first cycle, compared to LCO synthesized from commercial cobalt and lithium precursors (LCO_Com). Specific charge capacity and columbic efficiency also remained relatively stable after 60 charge/discharge cycles. The proposed recycling process of Co in the present work doesn’t require the use of the complicated and expensive solvent extraction method and thus it is simple, cost-effective, environmentally-friendly and could be used for recovering high purity critical metals such as Co and Li from spent LIBs at the industrial scale. Full article

The bottleneck of recycling chains for spent lithium-ion batteries (LIBs) is the recovery of valuable metals from the black matter that remains after dismantling and deactivation in pre‑treatment processes, which has to be treated in a subsequent step with pyrometallurgical and/or hydrometallurgical methods. In the course of this paper, investigations in a heating microscope were conducted to determine the high-temperature behavior of the cathode materials lithium cobalt oxide (LCO—chem., LiCoO₂) and lithium iron phosphate (LFP—chem., LiFePO₄) from LIB with carbon addition. For the purpose of continuous process development of a novel pyrometallurgical recycling process and adaptation of this to the requirements of the LIB material, two different reactor designs were examined. When treating LCO in an Al₂O₃ crucible, lithium could be removed at a rate of 76% via the gas stream, which is directly and purely available for further processing. In contrast, a removal rate of lithium of up to 97% was achieved in an MgO crucible. In addition, the basic capability of the concept for the treatment of LFP was investigated whereby a phosphorus removal rate of 64% with a simultaneous lithium removal rate of 68% was observed. Full article

The use of lithium-ion batteries (LIBs) has increased in recent years. Thus, efficient recycling is important. In this study, the Taguchi method was used to find the optimal selective lithium leaching parameters for spent LIB recycling. Orthogonal array, signal-to-noise ratio, and analysis of variance were employed to investigate the optimization of selective lithium leaching. The experimental parameters were heat treatment and leaching conditions. The lithium leaching ratio was analyzed by inductively coupled plasma (ICP). The reaction temperature was analyzed by thermogravimetry differential scanning calorimetry (TG-DSC) using lithium cobalt oxide (LCO) and carbon powder, and X-ray diffraction (XRD) was performed after heat treatment at different temperatures. From the XRD analysis, a Li₂CO₃ peak was observed at 700 °C. After heat treatment at 850 °C, a peak of Li₂O was confirmed as Li₂CO₃ decomposed into Li₂O and CO₂ over 723 °C. The Li₂O reacts with Co₃O₄ at a high temperature to form LCO. The phase of lithium in the LIB changes according to the conditional heat treatment, affecting the lithium leaching rates. As heat treatment conditions, N₂ atmosphere combined with 700 °C heat treatment is suitable, and the solid–liquid ratio is important as a leaching factor for selective lithium leaching. Full article