The Efficiency of Black Mass Preparation by Discharge and Alkaline Leaching for LIB Recycling

Abstract

Lithium-ion batteries (LIBs) are dangerous to recycle, as they pose a fire hazard when cut and contain various chemical hazards. If recycled safely, LIBs provide a rich secondary source for metals such as lithium and cobalt, while reducing the environmental impact of end-of-life LIBs. Discharging the spent LIBs in a 5 wt.% NaCl electrolyte at room temperature enables their safe dismantling. A sludge was observed to form during the LIB discharging, with a composition of 34.9 wt.% Fe, 35 wt.% O, 17.7 wt.% Al, 6.2 wt.% C, and 4.2 wt.% Na. The average electrolytic solution composition after the first discharge cycle contained only 12.6 mg/L Fe, 4.5 mg/L Li, 2.5 mg/L Mn, and trace amounts of Ni and Co. Separating the active cathode powder from the aluminum cathode with a 10 wt.% NaOH leach produced an aqueous filtrate with an Al metal purity of 99.7%. The leach composition consisted of 9558 mg/L Al, 13 mg/L Li, 8.7 mg/L Co, and trace amounts of Mn and Ni. The hydrometallurgical sample preparation processes in this study enables the production of a pure black mass with less than 0.05 wt.% Co, 0.2 wt.% Li, 0.02 wt.% Mn, and 0.02 wt.% Ni losses from the active cathode material.