A closed loop process for recycling spent lithium ion batteries

As lithium ion (Li-ion) batteries continue to increase their market share, recycling Li-ion batteries will become mandatory due to limited resources. We have previously demonstrated a new low temperature methodology to separate and synthesize cathode materials from mixed cathode materials. In this study we take used Li-ion batteries from a recycling source and recover active cathode materials, copper, steel, etc. To accomplish this the batteries are shredded and processed to separate the steel, copper and cathode materials: the cathode materials are then leached into solution; the concentrations of nickel, manganese and cobalt ions are adjusted so Ni sub(x)Mn sub(y) Co sub(z)(OH) sub(2) is precipitated. The precipitated product can then be reacted with lithium carbonate to form LiNi sub(x)Mn sub(y) Co sub(z)O sub(2). The results show that the developed recycling process is practical with high recovery efficiencies (~ 90%), and 1 ton of Li-ion batteries has the potential to generate $5013 profit margin based on materials balance.