Recovery of valuable metals from spent lithium-ion batteries through an ecofriendly catalytic approach

The rapid growth of lithium-ion batteries (LIBs) used in electric vehicles is amplifying the importance of recycling valuable materials from spent batteries. Current recycling technologies utilize extractive metallurgical processes to recover metals, particularly from cathode materials. However, pyrometallurgy requires high temperatures for smelting, while hydrometallurgy relies on toxic chemical reagents for leaching. Here, we present a catalytic strategy designed to overcome the energy and environmental challenges associated with metallurgical processes. The extraction reaction is conducted using an HxRuO2 catalyst in the presence of HNO3, H2, and CO2. Extraction is achieved through the selective hydrogenation of nitrate to ammonia, followed by the carbonation of leached metal species. The catalytic process successfully achieves nearly complete recovery of Co and Li as carbonates from LiCoO2. Furthermore, we demonstrate the versatility of this catalytic approach in recovering metals from various cathode materials, including spent LIBs. This newly developed one-pot method offers a promising industrial process for recycling valuable metals from spent batteries in an atom-efficient and environmentally friendly manner, without generating waste. [Display omitted] •Eco-friendly catalysts recover valuable metals from spent lithium-ion batteries.•Catalytic reactions are conducted at 110 °C in the presence of HNO3, H2, and CO2.•Complete recovery of Co and Li as carbonates from LiCoO2 is achieved.•This catalytic method recovers metals from various cathode materials effectively.•This one-pot catalytic reaction does not produce any toxic waste.