Direct reuse of aluminium and copper current collectors from spent lithium-ion batteries

Zhu, Pengcheng; Driscoll, Elizabeth H.; Dong, Bo; Sommerville, Roberto; Zorin, Anton; Slater, Peter R.; Kendrick, Emma

doi:10.1039/d2gc03940k

Cited by 17 publications

(14 citation statements)

References 46 publications

(59 reference statements)

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“…A large amount of graphite may partially reduce the cathode active materials, such as LCO and NCM during the high-temperature regeneration process, making the regeneration process incomplete. The binder currently used in the anode is mostly a water-based CMC-SBR combination, so the graphite and copper foil can be easily separated in water to obtain a complete copper foil, which can be directly reused. , In contrast, the copper powder obtained after crushing needs to be smelted before it can be remade into copper foil. Some researchers have tried to use water-based binders in the cathode, so that the separation of cathode active materials can also be completed by water immersion in the future, which may greatly improve the separation efficiency of cathode active materials …”

Section: Recovery System Based On Direct Recycling Methodsmentioning

confidence: 99%

Toward Direct Regeneration of Spent Lithium-Ion Batteries: A Next-Generation Recycling Method

Wang,

Ma,

Zhuang

et al. 2024

Chem. Rev.

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The popularity of portable electronic devices and electric vehicles has led to the drastically increasing consumption of lithium-ion batteries recently, raising concerns about the disposal and recycling of spent lithium-ion batteries. However, the recycling rate of lithium-ion batteries worldwide at present is extremely low. Many factors limit the promotion of the battery recycling rate: outdated recycling technology is the most critical one. Existing metallurgy-based recycling methods rely on continuous decomposition and extraction steps with high-temperature roasting/acid leaching processes and many chemical reagents. These methods are tedious with worse economic feasibility, and the recycling products are mostly alloys or salts, which can only be used as precursors. To simplify the process and improve the economic benefits, novel recycling methods are in urgent demand, and direct recycling/regeneration is therefore proposed as a next-generation method. Herein, a comprehensive review of the origin, current status, and prospect of direct recycling methods is provided. We have systematically analyzed current recycling methods and summarized their limitations, pointing out the necessity of developing direct recycling methods. A detailed analysis for discussions of the advantages, limitations, and obstacles is conducted. Guidance for future direct recycling methods toward large-scale industrialization as well as green and efficient recycling systems is also provided.

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Section: Recovery System Based On Direct Recycling Methodsmentioning

confidence: 99%

Toward Direct Regeneration of Spent Lithium-Ion Batteries: A Next-Generation Recycling Method

Wang,

Ma,

Zhuang

et al. 2024

Chem. Rev.

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“…111 In reducing thermal treatment, acetylene black from the black mass is utilized as a reducing agent to generate more soluble low-valent metals from metal oxide. It executes a clean separation of Al and Cu foils that can be reused aer a water wash. 112,113 A molten salt mixture drops down the high applied temperature. AlCl 3 -NaCl demonstrates the best performance with a 99.8% peeling-off efficiency.…”

Section: Thermal Treatmentmentioning

confidence: 99%

A review on spent lithium-ion battery recycling: from collection to black mass recovery

et al. 2023

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“…Three separate samples were collected at this stage. A 10% dilution was also made from the original 250 mL sample; again, three samples were retained from this dilution step [43]. The same procedure of filtering and diluting was also carried out for the leachate solution.…”

Section: Materials Characterisationmentioning

confidence: 99%

Acid-Assisted Separation of Cathodic Material from Spent Electric Vehicle Batteries for Recycling

Zorin

Song

Gastol

et al. 2023

Metals

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The recycling of lithium-ion batteries presents challenges due to the complex composition of waste streams generated by current processes. Achieving higher purity levels, particularly in the reclamation of aluminium metal and transition metal black mass, is essential for improved valorisation. In this study, we propose a high-efficiency, low-energy, and environmentally friendly method using organic acids to separate cathodic black mass from the aluminium current collector. The acids selected in this study all show >86% peeling efficiency with acetic acid showing 100% peeling efficiency of black mass from the current collector. The recovered materials were subjected to X-ray diffraction, electron microscopy, and elemental analysis techniques. We show that oxalic-acid-treated material exhibited two distinct active material components with a minimal change in mass ratio compared to the untreated material. We show by elemental analysis of the leachates that the majority of critical materials were retained in the black mass and limited aluminium was leached during the process, with almost 100% of Al recovery achieved. This methodology enables the production of high-purity concentrated aluminium and critical metal feedstocks (Mn, Co, Ni, and Li) for further hydro-metallurgical processes, upcycling of the cathode material, and direct recycling. The proposed approach offers significant potential for enhancing valorization in lithium-ion battery recycling, facilitating efficient separation and optimal recovery of valuable metals.

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Direct reuse of aluminium and copper current collectors from spent lithium-ion batteries

Abstract: The ever-increasing number of spent lithium-ion batteries (LIBs) has presented a serious waste-management challenge. Aluminium and copper current collectors are important components in LIBs and take up a weight percentage...

Cited by 17 publications

References 46 publications

Toward Direct Regeneration of Spent Lithium-Ion Batteries: A Next-Generation Recycling Method

Toward Direct Regeneration of Spent Lithium-Ion Batteries: A Next-Generation Recycling Method

A review on spent lithium-ion battery recycling: from collection to black mass recovery

Acid-Assisted Separation of Cathodic Material from Spent Electric Vehicle Batteries for Recycling

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