Search Results (294)

Lithium-ion batteries are major drivers to decarbonize road traffic and electric power systems. With the rising number of electric vehicles comes an increasing number of lithium-ion batteries reaching their end of use. After their usage, several strategies, e.g., reuse, repurposing, remanufacturing, or material recycling can be applied. In this context, remanufacturing is the favored end-of-use strategy to enable a new use cycle of lithium-ion batteries and their components. The process of remanufacturing itself is the restoration of a used product to at least its original performance by disassembling, cleaning, sorting, reconditioning, and reassembling. Thereby, disassembly as the first step is a decisive process step, as it creates the foundation for all further steps in the process chain and significantly determines the economic feasibility of the remanufacturing process. The aim of the disassembly depth is the replacement of individual cells to replace the smallest possible deficient unit and not, as is currently the case, the entire battery module or even the entire battery system. Consequently, disassembly sequences are derived from a priority matrix, a disassembly graph is generated, and the obstacles to non-destructive cell replacement are analyzed for two lithium-ion traction battery systems, to analyze the distinctions between battery electric vehicle (BEV) and plug-in hybrid electric vehicle (PHEV) battery systems and identify the necessary tools and fundamental procedures required for the effective management of battery systems within the circular economy. Full article

With the rapid economic development and the continuous growth in the demand for new energy vehicles and energy storage systems, a significant number of waste lithium-ion batteries are expected to enter the market in the future. Effectively managing the processing and recycling of these batteries to minimize environmental pollution is a major challenge currently facing the lithium-ion battery industry. This paper analyzes and compares the recycling strategies for different components of lithium-ion batteries, providing a summary of the main types of batteries, existing technologies at various pre-treatment stages, and recycling techniques for valuable resources such as heavy metals and graphite. Currently, pyrometallurgy and hydrometallurgy processes have matured; however, their high energy consumption and pollution levels conflict with the principles of the current green economy. As a result, innovative technologies have emerged, aiming to reduce energy consumption while achieving high recovery rates and minimizing the environmental impact. Nevertheless, most of these technologies are currently limited to the laboratory scale and are not yet suitable for large-scale application. Full article

The pyridinium phenolate punicine is a switchable molecule from Punica granatum. Depending on the pH, punicine exists as a cation, neutral molecule, anion, or dianion. In addition, punicine reacts to light, under the influence of which it forms radical species. We report on three punicine derivatives that possess an adamantyl, 2-methylnonyl, or heptadecyl substituent and on their performance in the flotation of lithium aluminate, an engineered artificial mineral (EnAM) for the recycling of lithium, e.g., from lithium-ion batteries. By optimizing the parameters: pH and light conditions (daylight, darkness), recovery rates of 92% of LiAlO₂ are achieved. In all cases, the flotation of the gangue material gehlenite (Ca₂Al[AlSiO₇]) is suppressed. IR, the contact angle, zeta potential measurements, TG-MS, and PXRD confirm that the punicines interact with the surface of LiAlO₂, which is covered by LiAl₂(OH)₇ after contact to water, resulting in a hydrophobization of the particle. The plasma pretreatment of the lithium aluminate has a significant influence on the flotation results and increases the recovery rates of lithium aluminate in blank tests by 58%. The oxidative plasma leads to a partial dehydratisation of the LiAl₂(OH)₇ and thus to a hydrophobization of the particles, while a reductive plasma causes a more hydrophilic particle surface. Full article

With the rapid growth of the lithium-ion battery (LIBs) market, recycling and re-using end-of-life LIBs to reclaim the critical Li, Co, Ni, and Mn has become an urgent task. Presently, high temperature, strong acid, and alkali conditions are required to extract blended critical metals (CM) from the typical battery cathode. Hence, there is a need for more effective recycling processes for recycling blended Li, Co, Ni, and their direct regeneration for re-use in LIBs. The goal of the offered paper is the development of recycling technology for degraded battery cathode-active materials based on the thermal decomposition of polyvinylidene fluoride (PVDF) using calcination and air-jet stripping of active materials. The proposed air-jet erosion method of calcined cathode material stripping from Al foil allows for the flexible industry-applicable separation process, which is damage-free for both particles and substrate. The CaO calcination air-jet separation process and equipment can significantly improve the PVDF decomposition and the separation efficiency of the cathode materials. It is demonstrated that low-temperature CaO calcination at 350–450 °C associated with air-jet separation of active material is characterized by low environmental impact, high purity of the recycled material, and low cost as compared to pyro- and hydrometallurgical methods. Full article

Lithium-ion batteries with an LFP cell chemistry are experiencing strong growth in the global battery market. Consequently, a process concept has been developed to recycle and recover critical raw materials, particularly graphite and lithium. The developed process concept consists of a thermal pretreatment to remove organic solvents and binders, flotation for anode–cathode separation, and hydrometallurgical processes for product recovery. It has been shown that a pretreatment step is necessary for efficient flotation. By increasing the thermal treatment temperatures up to 450 °C, recovery rates of up to 73% are achieved. Similar positive effects are observed with leaching, where leaching efficiencies increase with higher treatment temperatures up to 400 °C. The results indicate that the thermal treatment of the black mass significantly influences both flotation and hydrometallurgical processes. Full article

Global concerns about pollution reduction, associated with the continuous technological development of electronic equipment raises challenge for the future regarding lithium-ion batteries exploitation, use, and recovery through recycling of critical metals. Several human and environmental issues are reported, including related diseases caused by lithium waste. Lithium in Li-ion batteries can be recovered through various methods to prevent environmental contamination, and Li can be reused as a recyclable resource. Classical technologies for recovering lithium from batteries are associated with various environmental issues, so lithium recovery remains challenging. However, the emergence of membrane processes has opened new research directions in lithium recovery, offering hope for more efficient and environmentally friendly solutions. These processes can be integrated into current industrial recycling flows, having a high recovery potential and paving the way for a more sustainable future. A second method, biolexivation, is eco-friendly, but this point illustrates significant drawbacks when used on an industrial scale. We discussed toxicity induced by metals associated with Li to iron-oxidizing bacteria, which needs further study since it causes low recycling efficiency. One major environmental problem is the low efficiency of the recovery of Li from the water cycle, which affects global-scale safety. Still, electromembranes can offer promising solutions in the future, but there is needed to update regulations to actual needs for both producing and recycling LIB. Full article

Electric vehicle (EV) battery technology is at the forefront of the shift towards sustainable transportation. However, maximising the environmental and economic benefits of electric vehicles depends on advances in battery life cycle management. This comprehensive review analyses trends, techniques, and challenges across EV battery development, capacity prediction, and recycling, drawing on a dataset of over 22,000 articles from four major databases. Using Dynamic Topic Modelling (DTM), this study identifies key innovations and evolving research themes in battery-related technologies, capacity degradation factors, and recycling methods. The literature is structured into two primary themes: (1) “Electric Vehicle Battery Technologies, Development & Trends” and (2) “Capacity Prediction and Influencing Factors”. DTM revealed pivotal findings: advancements in lithium-ion and solid-state batteries for higher energy density, improvements in recycling technologies to reduce environmental impact, and the efficacy of machine learning-based models for real-time capacity prediction. Gaps persist in scaling sustainable recycling methods, developing cost-effective manufacturing processes, and creating standards for life cycle impact assessment. Future directions emphasise multidisciplinary research on new battery chemistries, efficient end-of-life management, and policy frameworks that support circular economy practices. This review serves as a resource for stakeholders to address the critical technological and regulatory challenges that will shape the sustainable future of electric vehicles. Full article

The recycling of lithium-ion batteries is increasingly important for both resource recovery and environmental protection. However, the complex composition of cathode and anode materials in these batteries makes the efficient separation of metal mixtures challenging. Hydrometallurgical methods, particularly liquid extraction, provide an effective means of separating metal ions, though they require periodic updates to their extraction systems. This study introduces a hydrophobic deep eutectic solvent composed of trioctylphosphine oxide, di(2-ethylhexyl)phosphoric acid, and menthol, which is effective for separating Ti(IV), Co(II), Mn(II), Ni(II), and Li⁺ ions from hydrochloric acid leachates of NMC (LiNi_xMn_yCo_1−x−yO₂) batteries with LTO (Li₄Ti₅O₁₂) anodes. By optimising the molar composition of the trioctylphosphine oxide/di(2-ethylhexyl)phosphoric acid/menthol mixture to a 4:1:5 ratio, high extraction efficiency was achieved. The solvent demonstrated stability over 10 cycles, and conditions for its regeneration were successfully established. At room temperature, the DES exhibited a density of 0.89 g/mL and a viscosity of 56 mPa·s, which are suitable for laboratory-scale extraction processes. Experimental results from a laboratory setup with mixer-settlers confirmed the efficiency of separating Ti(IV) and Co(II) ions in the context of their extraction kinetics. Full article

Battery recycling has become increasingly crucial in mitigating environmental pollution and conserving valuable resources. As demand for battery-powered devices rises across industries like automotive, electronics, and renewable energy, efficient recycling is essential. Traditional recycling methods, often reliant on manual labor, suffer from inefficiencies and environmental harm. However, recent artificial intelligence (AI) advancements offer promising solutions to these challenges. This paper reviews the latest developments in AI applications for battery recycling, focusing on methodologies, challenges, and future directions. AI technologies, particularly machine learning and deep learning models, are revolutionizing battery sorting, classification, and disassembly processes. AI-powered systems enhance efficiency by automating tasks such as battery identification, material characterization, and robotic disassembly, reducing human error and occupational hazards. Additionally, integrating AI with advanced sensing technologies like computer vision, spectroscopy, and X-ray imaging allows for precise material characterization and real-time monitoring, optimizing recycling strategies and material recovery rates. Despite these advancements, data quality, scalability, and regulatory compliance must be addressed to realize AI’s full potential in battery recycling. Collaborative efforts across interdisciplinary domains are essential to develop robust, scalable AI-driven recycling solutions, paving the way for a sustainable, circular economy in battery materials. Full article

The increasing use of lithium-containing materials highlights the urgent need for their recycling to preserve resources and protect the environment. Lithium-containing slags, produced during the pyrometallurgical process in lithium-ion battery recycling, represent an essential resource for lithium recovery efforts. While multiple methods for lithium recycling exist, it is crucial to emphasize environmentally sustainable approaches. This study employs dry forced triboelectrification (FTC) to recover valuable components from slag powder, commonly known as engineered artificial minerals (EnAMs). The FTC method is used to change the charge of the target material and achieve a neutral state while other materials remain charged. The downstream electrostatic separator enables the charged particles to be separated from the target material, which in this study is lithium aluminate. The results show that the method is effective, and lithium aluminate can be successfully enriched. Full article

This study explores the layer-by-layer (LBL) modification of polyacrylonitrile (PAN) hollow fibers for effective Mg²⁺/Li⁺ separation. It employs an LBL method of surface modification using polyelectrolytes, specifically aiming to enhance ion selectivity and improve the efficiency of lithium extraction from brines or lithium battery wastes, which is critical for battery recycling and other industrial applications. The modification process involves coating the hydrolyzed PAN fibers with alternating layers of positively charged polyelectrolytes, such as poly(allylamine hydrochloride) (PAH), polyethyleneimine (PEI), or poly(diallyldimethylammonium chloride) (PDADMAC) and negatively charged polyelectrolytes, such as poly(styrene sulfonate) (PSS), to form polyelectrolyte multilayers (PEMs). This study evaluates the modified membranes in Mg²⁺ and Li⁺ salt solutions, demonstrating significant improvements in selectivity for Mg²⁺/Li⁺ separation. PAH was identified as the optimal positively charged polyelectrolyte. PAN hollow fibers modified with ten bilayers of PAH/PSS achieved rejection rates of 95.4% for Mg²⁺ ions and 34.8% for Li⁺ ions, and a permeance of 0.39 LMH/bar. This highlights the potential of LBL techniques for effectively addressing the challenges of ion separation across a variety of applications. Full article

The market for lithium iron phosphate (LFP) batteries is projected to grow in the near future. However, recycling methods targeting LFP batteries, especially production scraps, are still underdeveloped. This study investigated the extraction of iron phosphate and lithium from LFP production scraps using selective leaching, considering technical and economic aspects. Two leaching agents, sulfuric acid (0.25–0.5 M, 25 °C, 1 h, 50 g/L) and citric acid (0.25–0.5 M, 25 °C, 1 h, 70 g/L) were compared; hydrogen peroxide (3–6%vv.) was added to prevent iron and phosphorous solubilization. Sulfuric acid leached up to 98% of Li and recovered up to 98% of Fe and P in the solid residues. Citric acid leached 18–26% of Li and recovered 98% of Fe and P. Totally, 28% of Li was precipitated for sulfuric acid process, while recovery with citric acid did not produce enough precipitate for a characterization. Sulfur is the main impurity present in the precipitates. The total operative costs associated with reagents and energy consumption of the sulfuric acid route were below 3.00 €/kg. In conclusion, selective leaching provided a viable and economic method to recycle LFP production scraps, and it is worth further research to optimize Lithium recovery. Full article

Amid South Africa’s shift towards electric vehicles (EVs), building a lithium-ion battery (LIB) recycling sector is essential for promoting sustainable development and generating employment opportunities. This study employs qualitative methodologies to collect insights from 12 critical stakeholders in the automotive, mining, and recycling sectors and academia to examine the feasibility and advantages of establishing such an industry. We implemented purposeful and snowball sampling to guarantee an exhaustive array of viewpoints. Thematic analysis of the interview data reveals that LIB recycling has substantial social, environmental, and economic implications. The results emphasize the pressing necessity of recycling infrastructure to mitigate environmental impacts and attract investment. The economic feasibility and employment potential of LIB recycling is promising despite the early stage of the EV industry in South Africa. These potentials are influenced by EV adoption rates, technological advancements, regulatory frameworks, and industry growth. In this sector, employment opportunities are available in various phases: battery collection, transportation, disassembly, testing, mechanical crushing, hydrometallurgical processes, valuable metal recovery, manufacturing, reuse, research and development, and administrative roles. Each of these roles necessitates a unique set of skills. This interdisciplinary research investigates vital elements of economic growth, employment creation, environmental sustainability, policymaking, technological innovation, and global collaboration. The study offers valuable guidance to policymakers and industry stakeholders trying to establish a sustainable and robust LIB recycling industry in South Africa by utilizing Transition Management Theory to develop a framework for improving the sustainability and circularity of the EV LIB recycling sector. Full article

Known for their high energy density, lithium-ion batteries have become ubiquitous in today’s technology landscape. However, they face critical challenges in terms of safety, availability, and sustainability. With the increasing global demand for energy, there is a growing need for alternative, efficient, and sustainable energy storage solutions. This is driving research into non-lithium battery systems. This paper presents a comprehensive literature review on recent advancements in non-lithium battery technologies, specifically sodium-ion, potassium-ion, magnesium-ion, aluminium-ion, zinc-ion, and calcium-ion batteries. By consulting recent peer-reviewed articles and reviews, we examine the key electrochemical properties and underlying chemistry of each battery system. Additionally, we evaluate their safety considerations, environmental sustainability, and recyclability. The reviewed literature highlights the promising potential of non-lithium batteries to address the limitations of lithium-ion batteries, likely to facilitate sustainable and scalable energy storage solutions across diverse applications. Full article