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Lithium-Ion Battery Recycling Processes

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Lithium-Ion Battery Recycling Processes ( lithium-ion-battery-recycling-processes )

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5 Fig. 5. Reduction in cell production energy by increasing use of recycled material [10]. Fig. 4. Comparison of cathode cost to constituent element cost. 5. Recycling Process Comparison From an energy and emissions viewpoint, re- covery of cathode material (especially LCO) is second in importance only to recovery of alumi- num, the largest contributor to cell material pro- duction energy and greenhouse gases [2]. The transition metals, generally produced from sul- fide ores, contribute most to SOx emissions, which are essentially eliminated by recycling. And the more materials recovered in as close to final usable form as possible, the more the net production impacts of the cells can be reduced. Figure 5 shows how energy for production of a cell can be reduced by increased use of recycled materials, enabled by recycling processes that re- cover materials in forms closer to direct use in new cell production. Both direct recycling and hydrometallurgical processes start with dismantling or shredding the cells. This step enables immediate recovery of the copper and aluminum foils as metals, although they still must be separated from each other. In contrast, pyrometallurgy feeds whole cells into a furnace and sends the copper to a mixed alloy product (where it is generally recovered by hy- drometallurgy), and the aluminum and lithium to the slag. These could be recovered by leaching, but the cost and energy requirements generally preclude this step. Use of an electric arc furnace sends most of the lithium to the furnace dust, from which it can easily be recovered [15]. The cells can be shredded prior to smelting (allowing recovery of the copper and aluminum foils), but this step would not only impose an added cost, it would remove a significant source of smelter en- ergy. The aluminum is oxidized and serves as a reductant in the furnace, decreasing the need for purchased fuel. One study reported using alumi- num cans instead of fuel [16]. The one U.S. Li- ion recycler (Retriev) does shred the cells, but does not smelt the resultant black mass (a mixture of active materials left after removal of the foils) itself; the company sells that intermediate product for smelting with transition-metal ores. Also in contrast to pyrometallurgical processing, both hy- drometallurgical processing and direct recycling are low-temperature, low energy processes, and do not require large scale, and therefore could be used locally or for home scrap, avoiding the need to transport the material. The main difference between direct recycling and hydrometallurgical processes is that direct re- cycling retains the cathode crystal morphology, while hydro uses strong acid to dissolve the cath- ode into its constituent ions, which are sent to aqueous solution. Working with strong acids in- creases process costs and complexity, prompting several studies proposing use of organic acids [17][18]. After leaching with acid, the dissolved constituents can be separated from each other and reused to manufacture new cathode material. Multiple stages of solvent extraction are gener- ally required to separate the cobalt and nickel ions, which have very similar properties and are

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