Search Results (493)

Recycling of lithium-ion batteries (LIBs) requires efficient separation of active material from current collectors to enable high-quality recovery of both the coating and the metal foil. In this study, a water-based delamination process for anode foils was systematically investigated under variations in temperature, particle size, ultrasonic power, and prior mechanical stressing of the particles. Mechanically cut and pre-folded foil pieces were treated in a batch setup at different temperatures (room temperature to 100 °C) and ultrasonic power levels (50 and 100%). Results show that higher temperatures strongly promote delamination, with 100% removal of the active layer achieved on the smooth foil side at 80 °C without ultrasonic treatment. Ultrasonic treatment at moderate power (50%) yielded greater delamination than at full power (100%), likely due to more effective cavitation dynamics at moderate intensity. Mechanical pre-stressing by folding significantly reduced delamination, with three folds effectively preventing separation. In comparison, mechanically comminuted particles from a granulator achieved similar delamination to three-folded particles after 5 min treatment, and higher delamination after 30 min. These findings highlight the importance of process parameters in achieving efficient aqueous delamination, providing insights for scaling low-energy recycling processes for LIB production scrap. Full article

In metallurgy, the quenching process often induces changes in certain material properties, such as hardness and ductility, through the rapid cooling of a workpiece in water, gas, oil, polymer, air, or other fluids. Given that lithium-ion batteries operate under relatively benign conditions, conventional rapid cooling does not significantly affect the property variations in their internal electrode materials during normal use. However, thermal runaway presents an exception due to its dramatic temperature fluctuations from room temperature to several hundred degrees Celsius. In this study, we investigated NCM811 cathodes in 18,650 batteries subjected to transient thermal runaway followed by rapid cooling using several advanced analytical techniques. The results reveal a phenomenon characterized by intergranular cracking within NCM811 cathode materials when exposed to rapid cooling during transient thermal runaway. Furthermore, lithium-ion cells utilizing reused NCM-182.4 electrodes in fresh electrolyte demonstrate a reversible capacity of 231.4 mAh/g after 30 cycles at 0.1 C, highlighting the potential for reusing NCM811 cathodes in the lithium-ion battery recycling process. These findings not only illustrate that NCM811 particles may experience intergranular cracking when subjected to rapid cooling during transient thermal runaway, but also the rapidly cooled NCM811 electrodes exhibit potential for reuse. Full article

The rapid growth of the electric vehicle (EV) market has highlighted the critical importance of securing a stable supply chain for lithium-ion battery (LIB) resources, thereby increasing the need for efficient recycling technologies. Among these, lithium recovery remains a major challenge due to significant losses during conventional processes. In this study, a chlorination roasting process was introduced to convert Li₂O in spent LIBs into LiCl, which was subsequently evaporated for selective lithium extraction and recovery. Roasting experiments were conducted under air, vacuum, and N₂ conditions at 800–1000 °C for 1–5 h, with Cl/Li molar ratios ranging from 0.5 to 8. The optimal condition for lithium evaporation, achieving 100% recovery, was identified as 1000 °C for 5 h, with a Cl/Li molar ratio of 6 under vacuum. Following lithium removal, residual valuable metals were extracted through H₂SO₄ leaching, and the effects of acid concentration and H₂O₂ addition on leaching efficiency were examined. The air-roasted samples exhibited the highest leaching performance, while the vacuum- and N₂-roasted samples showed relatively lower efficiency; however, the addition of H₂O₂ significantly enhanced leaching yields in these cases. Full article

Driven by the growing demand for sustainable resource utilization, the recovery of valuable constituents from spent lithium-ion batteries (LIBs) has attracted considerable attention, whereas conventional recycling processes remain energy-intensive, inefficient, and environmentally detrimental. Herein, an efficient and environmentally benign separation strategy integrating dielectrophoresis (DEP) and magnetophoresis (MAP) is proposed for isolating the primary components of “black mass” from spent LIBs, i.e., lithium iron phosphate (LFP) and graphite microparticles. A coupled electric–magnetic–fluid dynamic model is established to predict particle motion behavior, and a custom-designed microparticle separator is developed for continuous LFP–graphite separation. Numerical simulations are performed to analyze microparticle trajectories under mutual effects of DEP and MAP and to evaluate the feasibility of binary separation. Structural optimization revealed that the optimal separator configuration comprised an electrode spacing of 2 mm and a ferromagnetic body length of 5 mm with 3 mm spacing. Additionally, a numerical study also found that an auxiliary flow velocity ratio of 3 resulted in the best particle focusing effect. Furthermore, the effects of key operational parameters, including electric and magnetic field strengths and flow velocity, on particle migration were systematically investigated. The findings revealed that these factors significantly enhanced the lateral migration disparity between LFP and graphite within the separation channel, thereby enabling complete separation of LFP particles with high purity and recovery under optimized conditions. Overall, this study provides a theoretical foundation for the development of high-performance and environmentally sustainable LIBs recovery technologies. Full article

The recycling of spent lithium-ion batteries generates Na₂SO₄-containing wastewater, resulting in environmental problems and resource losses. This study investigates a treatment method employing bipolar membrane electrodialysis (BMED) to recover H₂SO₄ and NaOH from such wastewater. The acid and base recovery efficiencies, energy consumption, operational stability, and economic feasibility of two BMED configurations, i.e., two- and three-compartment systems, were systematically compared. The current density, initial concentrations of the feed, and initial concentrations and volumes of the acid and base were optimized under constant current conditions. The three-compartment system exhibited higher acid purity and stability, whereas the other system exhibited lower energy consumption and membrane degradation. Under optimal conditions, both systems successfully recovered H₂SO₄ and NaOH from the Na₂SO₄-containing wastewater. A techno-economic analysis based on a lab-scale process revealed that the two-compartment system exhibited cost effectiveness while the three-compartment system showed long-term operational stability. These findings suggest that BMED is a viable and effective solution for the treatment of Na₂SO₄-containing wastewater generated from battery recycling processes. Full article

Lithium (Li) ion sieve is considered to have great potential in the selective extraction of Li⁺ from complex Li⁺-containing brine owing to its cost-effectiveness, excellent adsorption performance, and environmental friendliness. Nevertheless, the defects of complex regulation and control of technological parameters in the preparation process of Li ion sieve and poor recycling efficiency limit its application. In this study, spinel-type H₄Ti₅O₁₂ ion sieves (HTO) were successfully prepared through a high-temperature solid-state method for recovering Li⁺ from aqueous resources. Through the experiment of optimizing the key preparation process parameters of HTO, it was found that the optimum preparation conditions were as follows: lithium ion source of CH₃COOLi‧H₂O, calcination temperature of 800 °C, and acid (HCl) washing concentration of 0.3 mol/L. The uptake of Li⁺ by HTO aligned with the pseudo-second-order kinetic model, which was a chemical adsorption process controlled by reversible Li–H ion exchange reaction. HTO exhibited extremely high regeneration cycle characteristics, and after five cycles, it retained 96.06% of its initial adsorption capacity. The present work highlighted that spinel-type HTO has high industrial application potential in the field of Li⁺ recovery from oilfield brine. Full article

As global efforts accelerate towards low-carbon transportation, power batteries from new energy vehicles (NEVs) have become critical resources, presenting both opportunities and environmental challenges. These batteries contain significant quantities of critical metals—such as nickel, cobalt, and lithium—that are crucial for the energy transition but face substantial supply risks. Megacities like Shanghai, leaders in NEV adoption, increasingly serve as significant reservoirs of these valuable materials. Maximizing the recovery of these metals from retired NEV batteries is therefore essential for enhancing resource security, minimizing environmental impacts, and promoting urban sustainability. This study employs a dynamic material flow model to estimate the demand and retirement volumes of critical metals in NEV power batteries in Shanghai from 2014 to 2050. Rather than assessing specific recycling technologies, this research evaluates the broader strategic, environmental, and economic benefits of recycling. Key findings include the following: (1) Annual peak demand for critical metals will range from approximately 0.3 to 34 thousand tons, with domestic cobalt production expected to be inadequate beyond 2029 under high-intensity adoption scenarios. (2) By 2050, the volume of discarded critical metals will surpass the demand for newly mined resources, reaching annual volumes of up to 29 thousand tons. The cumulative recoverable quantities from 2014 to 2050 are projected to range between 0.7 and 227 thousand tons for nickel, 2 and 43 thousand tons for cobalt, and 0.6 and 24 thousand tons for lithium. (3) Recycling these critical metals significantly reduces dependency on primary extraction, lowers greenhouse gas emissions, prevents secondary pollution, and ensures economic sustainability. The study concludes with targeted policy recommendations to facilitate efficient and large-scale recovery of critical metals from NEV batteries in Shanghai. Harnessing this urban resource stream can reinforce China’s strategic metal supply chain and support the city’s sustainable, circular, and low-carbon development goals. Full article

Waste lithium-ion batteries (LIBs), which usually contain dangerous organic electrolytes and transition metals, including nickel, cobalt, iron, and manganese, can hurt the environment and human health. Substantial advancements have been achieved in employing high-efficiency, economical, and environmentally sustainable techniques for the recycling of spent LIBs. Converting exhausted LIBs into efficient energy conversion catalysts straightforwardly is a good strategy for addressing metal resource constraints and clean energy concerns. This transforms waste cathodes, anodes, binders, and separators from depleted LIBs into electrocatalysts free of platinum group metals for the oxygen evolution reaction (OER) and the oxygen reduction reaction (ORR). The composite, including transition metal oxide, graphene oxide, and carbon mass, will be synthesized from spent LIBs, demonstrating enhanced electrocatalytic activity. Utilizing “waste-to-energy” methods for used LIBs as catalysts would provide substantial benefits in environmental preservation and the effective production of functional materials in metal–air batteries. Full article

The growing demand for lithium-ion batteries (LIBs) has led to an urgent need for sustainable recycling strategies for spent cathode materials. In this study, a mechanochemical approach was developed for the recovery of lithium and cobalt from end-of-life LiCoO₂ cathodes using high-energy ball milling. For the first time, aluminum and carbon were employed as internal reducing agents, facilitating the in situ decomposition of LiCoO₂ into CoO, Li₂O, and metallic Co. X-ray diffraction analysis confirmed significant structural disorder, phase transitions, and the formation of CoO, AlCo, and spinel-like CoAl₂O₄. The Taguchi method was applied to optimize milling parameters, identifying 800 rpm, 60 min, and a ball-to-powder ratio of 50:1 as the most effective conditions for structural activation. Subsequent ammonia leaching under fixed conditions (3.0 M NH₃·H₂O, 1.0 M (NH₄)₂CO₃, 60 °C, 25 mL/g, 6 h) demonstrated high recovery efficiencies: up to 94.6% for lithium and 83.7% for cobalt in the best-performing samples. These results highlight the synergistic benefits of mechanical activation and reductant-assisted phase engineering for enhancing metal recovery. The proposed method offers a simple, scalable, and eco-friendly route for the hydrometallurgical recycling of LIB cathodes without requiring extensive chemical pretreatment. Full article

The surging demand for lithium-ion batteries (LIBs) has intensified the need for sustainable recovery of critical metals such as lithium, manganese, cobalt, and nickel from spent cathodes. While conventional hydrometallurgical and pyrometallurgical methods are widely used, they involve high energy consumption, hazardous waste generation, and complex processing steps, underscoring the urgency of developing eco-friendly alternatives. This study presents a novel, water-enhanced deep eutectic solvent (DES) system composed of choline chloride and D-glucose for the efficient leaching of valuable metals from spent LiMn-based battery cathodes. The DES was synthesized under mild conditions and applied to dissolve cathode powder, with leaching performance optimized by varying temperature and duration. Under optimal conditions (100 °C, 24 h), exceptional recovery efficiencies were achieved: 98.9% for lithium, 98.4% for manganese, and 71.7% for nickel. Material characterization using X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), and inductively coupled plasma mass spectrometer (ICP-MS) confirm effective phase dissolution and metal release. Although this DES system requires relatively higher temperature and longer reaction time compared to traditional acid leaching, it offers clear advantages in terms of non-toxicity, biodegradability, and elimination of strong oxidizing agents. These results demonstrate the potential of water-enhanced choline chloride–glucose DES as a green alternative for future development in sustainable battery recycling, supporting circular economy objectives. Full article

Biomass resources are excellent candidates for carbon electrode materials due to their abundance, renewability, and biodegradability. Herein, the solanaceous crop Tobacco Straw, a rich agricultural by-product, was utilized to prepare biomass-derived carbon material (TsC) and applied as an anode in lithium-ion batteries (LIBs). Doping or composite formation is considered to enhance the electrochemical performance. Doping extra nitrogen (N) atoms into the TsC (denoted as TsNC) demonstrated exceptional reversible specific capacity (475.9 mA h g⁻¹ at the current density of 60 mA g⁻¹ after 500 cycles) and remarkable long-term cycling stability (142.9 mA h g⁻¹ even at a high current density of 1.5 A g⁻¹ after 1000 cycles, much larger than that of TsC), attributed to the increased lithium-ion (Li-ion) adsorption sites including graphitic-N, pyrrolic-N, and pyridinic-N. Furthermore, kinetic analysis revealed that a prominent predominant surface capacitive-controlled behavior was responsible for the superior rate performance of TsNC, which could facilitate rapid charging and discharging at high rates. This work offers valuable insights into the application and modification of nitrogen-doped biomass-derived carbons with outstanding electrochemical properties for LIBs. The strategy also sheds light on enabling waste recycling and generating economic benefits. Full article

The sustainable recycling of valuable metals from spent lithium-ion batteries (LIBs) is critical for resource conservation and environmental protection but remains challenging due to the complex coexistence of target and impurity metals. This study systematically investigates the selective leaching behaviors of metals (Co, Li, Cu, Fe, Al) in phosphoric acid media, revealing that lithium could be preferentially extracted in mild acidic conditions (0.8 mol/L H₃PO₄), while complete dissolution of both Li and Co was achieved in concentrated acid (2.0 mol/L H₃PO₄). Kinetic analysis demonstrated that metal leaching followed a chemically controlled mechanism, with distinct extraction sequences: Li > Cu~Co > Fe > Al in dilute acid and Cu > Al~Li > Fe > Co in concentrated acid. Furthermore, we developed a closed-loop process wherein oxalic acid simultaneously precipitates Co/Li while regenerating H₃PO₄, enabling acid reuse with minimal efficiency loss during cyclic leaching. These findings establish a single-step phosphoric acid leaching strategy for selective metal recovery, governed by tunable acid concentration and reaction kinetics, offering a sustainable pathway for LIBs recycling. Full article

As China advances toward its 2060 carbon neutrality goal, the electrification of inland waterway shipping has emerged as a strategic pathway for reducing emissions. This study constructs a 2025–2060 dynamic material flow analysis framework that integrates three core dimensions: (1) all-electric ships (AES) diffusion, estimated via a GDP-elasticity model and carbon emission accounting; (2) battery technology evolution, including lithium iron phosphate and solid-state batteries; and (3) recycling system improvements, incorporating direct recycling, cascade utilization, and metallurgical processes. The research sets up three AES penetration scenarios, two battery technologies, and three recycling technology improvement scenarios, resulting in seven combination scenarios for analysis. Through multi-scenario simulations, it reveals synergistic pathways for resource security and decarbonization goals. Key findings include that to meet carbon reduction targets, AES penetration in inland shipping must reach 25.36% by 2060, corresponding to cumulative new ship constructions of 51.5–79.9k units, with total lithium demand ranging from 49.1–95.9 kt, and recycling potential reaching 5.4–25.2 kt. Results also reveal that under current allocation assumptions, the AES sector may face lithium shortages between 2047 and 2057 unless recycling rates improve or electrification pathways are optimized. The work innovatively links battery tech dynamics and recycling optimization for China’s inland shipping and provides actionable guidance for balancing decarbonization and lithium resource security. Full article

Although approximately half of global lithium consumption is used in the rechargeable battery industry, lithium is also in demand for other specialized applications, such as high-temperature lubricants, ceramics, glass, and pharmaceuticals. The growing need for efficient lithium recovery and recycling underscores the importance of fast and accurate analytical tools for determining lithium concentrations in non-compliant and waste materials generated by industrial processes. In this paper, we present a machine learning-based procedure utilizing Laser-Induced Breakdown Spectroscopy (LIBS) to accurately quantify lithium concentrations in lithium-rich non-compliant materials derived from the industrial production of enamels used for coating metallic surfaces. This procedure addresses challenges such as strong self-absorption and matrix effects, which limit the effectiveness of conventional univariate calibration methods. By employing a multivariate approach, we developed a single model capable of quantifying lithium content across a wide concentration range. A comparison of the LIBS results with those obtained using conventional laboratory analysis (Inductively Coupled Plasma–Optical Emission Spectrometry, ICP-OES) confirms that LIBS can deliver the speed, precision, and reliability required for potential routine applications in the lithium recovery and recycling industry. Full article

With the growing wave of end-of-life new energy vehicles, the recycling of lithium iron phosphate (LFP) batteries has become increasingly imperative. In contrast to conventional pyrometallurgical and hydrometallurgical approaches, recent efforts have shifted toward innovative recycling strategies and emerging applications for spent LFP materials. During battery operation, the irreversible oxidation of Fe²⁺ to Fe³⁺ often leads to lithium loss and performance degradation. To address this, various approaches—such as electrochemical delamination and ultrasonic separation—have been developed to efficiently detach cathode materials from current collectors, followed by thermal or wet-chemical regeneration to restore their electrochemical activity. Beyond conventional regeneration, the upcycling of spent LFP into value-added functional materials offers a sustainable pathway for resource reutilization. Notably, phosphorus extracted from LFP can be converted into slow-release fertilizers, broadening the scope of secondary applications. As the volume of spent LFP batteries continues to rise, there is an urgent need to establish an integrated recycling framework that harmonizes environmental impact, technical efficiency, and economic viability. Henceforth, this review summarizes recent advances in LFP recycling and upcycling, discusses critical challenges, and provides strategic insights for the sustainable and high-value reuse of spent LFP cathodes. Full article