Near zero waste Hydrometallurgy for spent Li-Ion batteries- multi element recovery for maximized recycling

Purpose and goal

In this project near zero waste hydrometallurgy for spent Li-Ion batteries for maximized recycling efficiency was developed. In the project Li-ion batteries were recycled using thermal pre-treatment for improved electrolyte recovery. Impurities were removed using cementation and precipitation. A flexible process for valuable and critical metals was developed at Chalmers. Process allows an efficient metal separation and generates products with a battery grade. Sequential recovery allows to use modular system so technology can be transported/build on the recycling site.

Expected effects and result

Pyrolysis was very effective to recover the electrolyte. Metal impurities were removed with 97% efficiency using the precipitation. Lithium was also recovered, and product value was very high. However, the purity was only moderate, and product requires further purification. On the other hand, very high purity products were achieved after solvent extraction process. Purity of manganese product was 99.95% and recovery rate was over 96%. Cobalt purity was 99.96% and recovery rate was over 95%. Nickel was recovered as last with a purity over 99.9% and recovery rate over 97%.

Planned approach and implementation

The project had four main partners. German company Accurec Recycling GbmH did a mechanical processing and electrolyte recovery via pyrolysis. German Aachen university recovered lithium and efficiently removed the impurities. Swedish Chalmers University and MEAB AB developed a technology for metal recovery and product purification. MEAB also designed the modular system for a container type of the pilot plant for flexible transportation and processing. Project had 6 work packages equally distributed among partners.