Alternative Process Chain via Selective Leaching, Flotation and Smelting for LIB Recycling

The increasing demand for batteries, particularly in the electric vehicle and renewable energy sectors, necessitates sustainable and efficient methods for battery recycling. This work presents a comprehensive proof of concept for a battery recycling process chain that employs selective leaching with an organic acid, flotation, and smelting to recover valuable metals. This process aims to extract lithium, graphite, cobalt-nickel alloy, and manganese from spent batteries.<br/>Selective leaching with an organic acid was utilized as the initial step to extract lithium from black mass. This method ensures the targeted recovery of lithium without compromising the quality of other valuable components. The leaching process generated a lithium-rich solution, which underwent subsequent purification steps to obtain a high-purity lithium salt.<br/>The flotation technique was employed to recover graphite, a critical component used in battery anodes. By selectively floating graphite particles, the process achieved efficient separation from other materials, enhancing the purity and recovery rate of graphite.<br/>Following flotation, the remaining battery black mass was subjected to pyrometallurgy to recover cobalt, nickel, and manganese. Pyrometallurgy involves high-temperature processing, enabling the formation of a cobalt-nickel alloy, that can be further treated to produce precursor material for battery production. Manganese, on the other hand, was found in the slag produced during pyrometallurgical treatment.<br/>The developed process chain for battery recycling offers multiple advantages. Firstly, selective leaching ensures the recovery of lithium, a crucial metal for modern batteries, with high purity and minimal waste generation. Secondly, flotation enables efficient graphite recovery, addressing the increasing demand for this material. Lastly, smelting yields a valuable cobalt-nickel alloy and manganese is found in the produced slag, potentially opening up possibilities for further recovery.<br/>The proof of concept presented in this work demonstrates the feasibility of the proposed recycling process chain for batteries. By integrating selective leaching, flotation, and pyrometallurgical treatment, this approach provides a comprehensive solution for recovering key battery materials. The successful extraction of lithium, graphite, cobalt-nickel alloy, and identification of manganese in the slag highlights the potential for resource sustainability and circularity in the battery industry.