The InnoRec Process: A Comparative Study of Three Mainstream Routes for Spent Lithium-ion Battery Recycling Based on the Same Feedstock

Hao Qiu (), Daniel Goldmann, Christin Stallmeister, Bernd Friedrich, Maximilian Tobaben, Arno Kwade, Christoph Peschel, Martin Winter, Sascha Nowak, Tony Lyon and Urs A. Peuker
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Hao Qiu: Institute of Mineral and Waste Processing, Recycling and Circular Economy Systems (IFAD), Clausthal University of Technology, Walther-Nernst-Straße 9, 38678 Clausthal-Zellerfeld, Germany
Daniel Goldmann: Institute of Mineral and Waste Processing, Recycling and Circular Economy Systems (IFAD), Clausthal University of Technology, Walther-Nernst-Straße 9, 38678 Clausthal-Zellerfeld, Germany
Christin Stallmeister: Institute of Process Metallurgy and Metal Recycling (IME), RWTH Aachen University, Intzestr. 3, 52056 Aachen, Germany
Bernd Friedrich: Institute of Process Metallurgy and Metal Recycling (IME), RWTH Aachen University, Intzestr. 3, 52056 Aachen, Germany
Maximilian Tobaben: Institute for Particle Technology (iPAT), TU Braunschweig, Volkmaroder Str. 5, 38104 Braunschweig, Germany
Arno Kwade: Institute for Particle Technology (iPAT), TU Braunschweig, Volkmaroder Str. 5, 38104 Braunschweig, Germany
Christoph Peschel: MEET Battery Research Center, University of Münster, Corrensstr. 46, 48149 Münster, Germany
Martin Winter: MEET Battery Research Center, University of Münster, Corrensstr. 46, 48149 Münster, Germany
Sascha Nowak: MEET Battery Research Center, University of Münster, Corrensstr. 46, 48149 Münster, Germany
Tony Lyon: Institute of Mechanical Process Engineering and Mineral Processing (MVTAT), TU Bergakademie Freiberg, 09599 Freiberg, Germany
Urs A. Peuker: Institute of Mechanical Process Engineering and Mineral Processing (MVTAT), TU Bergakademie Freiberg, 09599 Freiberg, Germany

Sustainability, 2024, vol. 16, issue 9, 1-28

Abstract: Among the technologies used for spent lithium-ion battery recycling, the common approaches include mechanical treatment, pyrometallurgical processing and hydrometallurgical processing. These technologies do not stand alone in a complete recycling process but are combined. The constant changes in battery materials and battery design make it a challenge for the existing recycling processes, and the need to design efficient and robust recycling processes for current and future battery materials has become a critical issue today. Therefore, this paper simplifies the current treatment technologies into three recycling routes, namely, the hot pyrometallurgical route, warm mechanical route and cold mechanical route. By using the same feedstock, the three routes are compared based on the recovery rate of the six elements (Al, Cu, C, Li, Co and Ni). The three different recycling routes represent specific application scenarios, each with their own advantages and disadvantages. In the hot pyrometallurgical route, the recovery of Co is over 98%, and the recovery of Ni is over 99%. In the warm mechanical route, the recovery of Li can reach 63%, and the recovery of graphite is 75%. In the cold mechanical route, the recovery of Cu can reach 75%, and the recovery of Al is 87%. As the chemical compositions of battery materials and various doping elements continue to change today, these three recycling routes could be combined in some way to improve the overall recycling efficiency of batteries.

Keywords: battery recycling; lithium; graphite; electrolyte; mechanical processing; pyrometallurgy; thermal treatment; pyrolysis; flotation; hydrometallurgy (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2024
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