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<p>Rapidly growing demand for lithium-ion batteries (LIBs) necessitates a significant expansion of LIB recycling to ensure adequate supply and avoid waste buildup. Traditional hydrometallurgical LIB recycling processes use super-stoichiometric quantities of acid and base and generate large volumes of salt waste that pose an environmental burden. Electrochemical regeneration of acid and base from salt offers a zero-waste alternative but faces challenges with respect to throughput and energy consumption, with current densities typically limited to ≤ 100 mA/cm<sup>2</sup> and energy demands &gt; 0.10 kWh/mol. These limitations stem from a reliance on ion exchange membranes (IEMs), which lead to high cell resistance. This study reports a hydrometallurgical process to recycle lithium cobalt oxide (LCO) and lithium nickel manganese cobalt oxide (NMC) cathodes using acid and base electrochemically generated from a Li<sub>2</sub>SO<sub>4</sub> electrolyte. The electrochemical cell used contains no IEMs, enabling excellent energy efficiency between 0.033 and 0.097 kWh/mol at current densities up to 500 mA/cm<sup>2</sup> and imparting a robust tolerance for impurities that typically foul IEMs. The produced acid and base are found to be competent for etching and recovering &gt; 90% of the valuable metals from LIBs at industrially relevant pulp densities up to 66 g/L and are readily regenerated from the salt solution left at the end of the metal recovery process.</p>

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Li-ion battery recycling by energy-efficient, high-throughput Li2SO4 salt splitting in a diaphragm flow cell

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月20日

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  • Jason W. Misleh,
  • J. Gage Wright,
  • Benjamin P. Charnay,
  • Matthew W. Kanan

摘要

Rapidly growing demand for lithium-ion batteries (LIBs) necessitates a significant expansion of LIB recycling to ensure adequate supply and avoid waste buildup. Traditional hydrometallurgical LIB recycling processes use super-stoichiometric quantities of acid and base and generate large volumes of salt waste that pose an environmental burden. Electrochemical regeneration of acid and base from salt offers a zero-waste alternative but faces challenges with respect to throughput and energy consumption, with current densities typically limited to ≤ 100 mA/cm2 and energy demands > 0.10 kWh/mol. These limitations stem from a reliance on ion exchange membranes (IEMs), which lead to high cell resistance. This study reports a hydrometallurgical process to recycle lithium cobalt oxide (LCO) and lithium nickel manganese cobalt oxide (NMC) cathodes using acid and base electrochemically generated from a Li2SO4 electrolyte. The electrochemical cell used contains no IEMs, enabling excellent energy efficiency between 0.033 and 0.097 kWh/mol at current densities up to 500 mA/cm2 and imparting a robust tolerance for impurities that typically foul IEMs. The produced acid and base are found to be competent for etching and recovering > 90% of the valuable metals from LIBs at industrially relevant pulp densities up to 66 g/L and are readily regenerated from the salt solution left at the end of the metal recovery process.