Closed-Loop Recycling of Lithium, Cobalt, Nickel, and Manganese from Waste Lithium-Ion Batteries of Electric Vehicles

With the growing awareness to protect the urban environment and the increasing demand for strategic materials, recycling of postconsumer lithium-ion batteries has become imperative. This study aims to recover lithium, cobalt, nickel, and manganese from a LiNi0.15Mn0.15Co0.70O2 cathode material of spent lithium-ion batteries of an electric vehicle. By utilizing systematic experimental and theoretical approaches based on the design of experiment and response surface methodology, the best leachant between HCl and H2SO4 + H2O2 and the optimal operating conditions are determined. Leaching with 1.0 M H2SO4 mixed with 0.62 wt % H2O2 at a liquid-to-solid ratio of 25.8 mL g–1 and a temperature of 51 °C for 60 min results in ∼100% recovery of all four metals. After leaching, cobalt, nickel, and manganese are coprecipitated as Ni0.15Mn0.15Co0.70(OH)2 at pH above 11, while lithium is precipitated as lithium carbonate. These precipitates are mixed and sintered to generate a new cathode material, which is used to make a battery with high electrochemical performance. Valorization of spent lithium-ion batteries from electric vehicles enables conserving natural resources and protecting ecosystems, both of which enable the long-term sustainability of the biosphere while at the same time contributing to the circular economy.