Optimizing Recycling Processes for Mixed LFP/NMC Lithium-Ion Batteries: A Comparative Study of Acid-Excess and Acid-Deficient Leaching
This study explores the optimization of hydrometallurgical processes for recycling lithium-ion batteries (LIBs) containing a mixture of lithium iron phosphate (LFP) and nickel–manganese–cobalt (NMC) cathodes. Two approaches were investigated: acid-excess leaching and acid-deficient leaching with res...
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MDPI AG
2025-01-01
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| Online Access: | https://www.mdpi.com/2075-4701/15/1/74 |
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| author | Pierric Hubert Angelina Noclain Safi Jradi Alexandre Chagnes |
| author_facet | Pierric Hubert Angelina Noclain Safi Jradi Alexandre Chagnes |
| author_sort | Pierric Hubert |
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| description | This study explores the optimization of hydrometallurgical processes for recycling lithium-ion batteries (LIBs) containing a mixture of lithium iron phosphate (LFP) and nickel–manganese–cobalt (NMC) cathodes. Two approaches were investigated: acid-excess leaching and acid-deficient leaching with residue recirculation. A design of experiments (DoE) framework was applied to assess the impact of key parameters, including sulfuric acid and hydrogen peroxide concentrations, as well as solid-to-liquid (S/L) ratios, on the dissolution yields of target metals (Ni, Mn, Co, and Li). Acid-excess leaching achieved nearly complete dissolution of target metals but required additional purification steps to remove impurities. Acid-deficient leaching with a 60% recirculation of leaching residue improved dissolution yields by up to 12.5%, reduced reagent consumption, and minimized operational complexity. The study also evaluated separation strategies for manganese and cobalt through solvent extraction. Results indicate that while acid-excess leaching offers higher yields, acid-deficient leaching with residue recirculation is more cost-effective and environmentally friendly. These findings provide valuable insights for developing sustainable LIB recycling technologies. |
| format | Article |
| id | doaj-art-d20b6307a3a64e2bbe81eee678aed28f |
| institution | Kabale University |
| issn | 2075-4701 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
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| series | Metals |
| spelling | doaj-art-d20b6307a3a64e2bbe81eee678aed28f2025-01-24T13:41:36ZengMDPI AGMetals2075-47012025-01-011517410.3390/met15010074Optimizing Recycling Processes for Mixed LFP/NMC Lithium-Ion Batteries: A Comparative Study of Acid-Excess and Acid-Deficient LeachingPierric Hubert0Angelina Noclain1Safi Jradi2Alexandre Chagnes3Centre National Supérieur de Recherche Scientifique (CNRS), Université de Lorraine, GeoRessources, 54000 Nancy, FranceCentre National Supérieur de Recherche Scientifique (CNRS), Université de Lorraine, GeoRessources, 54000 Nancy, FranceLaboratoire Lumière, Nanomatériaux et Nanotechnologies, Université Technologique de Troyes, 10004 Troyes, FranceCentre National Supérieur de Recherche Scientifique (CNRS), Université de Lorraine, GeoRessources, 54000 Nancy, FranceThis study explores the optimization of hydrometallurgical processes for recycling lithium-ion batteries (LIBs) containing a mixture of lithium iron phosphate (LFP) and nickel–manganese–cobalt (NMC) cathodes. Two approaches were investigated: acid-excess leaching and acid-deficient leaching with residue recirculation. A design of experiments (DoE) framework was applied to assess the impact of key parameters, including sulfuric acid and hydrogen peroxide concentrations, as well as solid-to-liquid (S/L) ratios, on the dissolution yields of target metals (Ni, Mn, Co, and Li). Acid-excess leaching achieved nearly complete dissolution of target metals but required additional purification steps to remove impurities. Acid-deficient leaching with a 60% recirculation of leaching residue improved dissolution yields by up to 12.5%, reduced reagent consumption, and minimized operational complexity. The study also evaluated separation strategies for manganese and cobalt through solvent extraction. Results indicate that while acid-excess leaching offers higher yields, acid-deficient leaching with residue recirculation is more cost-effective and environmentally friendly. These findings provide valuable insights for developing sustainable LIB recycling technologies.https://www.mdpi.com/2075-4701/15/1/74acid-deficient leachingacid-excess leachingNMC-LFP black masslithium-ion batteriesrecyclingsolvent extraction |
| spellingShingle | Pierric Hubert Angelina Noclain Safi Jradi Alexandre Chagnes Optimizing Recycling Processes for Mixed LFP/NMC Lithium-Ion Batteries: A Comparative Study of Acid-Excess and Acid-Deficient Leaching Metals acid-deficient leaching acid-excess leaching NMC-LFP black mass lithium-ion batteries recycling solvent extraction |
| title | Optimizing Recycling Processes for Mixed LFP/NMC Lithium-Ion Batteries: A Comparative Study of Acid-Excess and Acid-Deficient Leaching |
| title_full | Optimizing Recycling Processes for Mixed LFP/NMC Lithium-Ion Batteries: A Comparative Study of Acid-Excess and Acid-Deficient Leaching |
| title_fullStr | Optimizing Recycling Processes for Mixed LFP/NMC Lithium-Ion Batteries: A Comparative Study of Acid-Excess and Acid-Deficient Leaching |
| title_full_unstemmed | Optimizing Recycling Processes for Mixed LFP/NMC Lithium-Ion Batteries: A Comparative Study of Acid-Excess and Acid-Deficient Leaching |
| title_short | Optimizing Recycling Processes for Mixed LFP/NMC Lithium-Ion Batteries: A Comparative Study of Acid-Excess and Acid-Deficient Leaching |
| title_sort | optimizing recycling processes for mixed lfp nmc lithium ion batteries a comparative study of acid excess and acid deficient leaching |
| topic | acid-deficient leaching acid-excess leaching NMC-LFP black mass lithium-ion batteries recycling solvent extraction |
| url | https://www.mdpi.com/2075-4701/15/1/74 |
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