Selective and Closed-Loop Recycling of Different Metals from Spent Lithium-Ion Batteries Through Phosphoric Acid Leaching: Parameter Optimization and Regulation of Reaction Kinetics

Linling Guo, Zihao Chen, Yutong Guo, Chaoyang Chen, Yan Wang and Xiangping Chen ()
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Linling Guo: College of Chemistry and Chemical Engineering, Hunan Normal University, Changsha 410081, China
Zihao Chen: College of Chemistry and Chemical Engineering, Hunan Normal University, Changsha 410081, China
Yutong Guo: College of Chemistry and Chemical Engineering, Hunan Normal University, Changsha 410081, China
Chaoyang Chen: College of Chemistry and Chemical Engineering, Hunan Normal University, Changsha 410081, China
Yan Wang: College of Chemistry and Chemical Engineering, Hunan Normal University, Changsha 410081, China
Xiangping Chen: College of Chemistry and Chemical Engineering, Hunan Normal University, Changsha 410081, China

Sustainability, 2025, vol. 17, issue 17, 1-18

Abstract: The sustainable recycling of valuable metals from spent lithium-ion batteries (LIBs) is critical for resource conservation and environmental protection but remains challenging due to the complex coexistence of target and impurity metals. This study systematically investigates the selective leaching behaviors of metals (Co, Li, Cu, Fe, Al) in phosphoric acid media, revealing that lithium could be preferentially extracted in mild acidic conditions (0.8 mol/L H 3 PO 4 ), while complete dissolution of both Li and Co was achieved in concentrated acid (2.0 mol/L H 3 PO 4 ). Kinetic analysis demonstrated that metal leaching followed a chemically controlled mechanism, with distinct extraction sequences: Li > Cu~Co > Fe > Al in dilute acid and Cu > Al~Li > Fe > Co in concentrated acid. Furthermore, we developed a closed-loop process wherein oxalic acid simultaneously precipitates Co/Li while regenerating H 3 PO 4 , enabling acid reuse with minimal efficiency loss during cyclic leaching. These findings establish a single-step phosphoric acid leaching strategy for selective metal recovery, governed by tunable acid concentration and reaction kinetics, offering a sustainable pathway for LIBs recycling.

Keywords: spent lithium-ion batteries; selective recovery; leaching; different metals; phosphoric acidic media (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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