3292 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
The recovery of the electrolyte would appear from
literature to be problematic and best treated via calcina-
tion at 1000°C or lower temperature evaporation while
drying other components. observed It is worth noting (
Hantanasirisakul, K &Sawangphruk, M, 2023) that cur-
rently electrolyte material is being recovered to comply
with US and EU environmental regulations rather than
for economic reasons. The key focus for future electrolyte
development is that it should be safe, green and sustainable.
Electrode Separation and Recovery
The process of electrode separation and recovery is a crucial
aspect of the Direct Recycling method. It involves the sepa-
ration and subsequent recuperation of mixtures of electrode
materials. The techniques used in this process are tailored
to uniquely leverage the specific properties of each material.
One such property is hydrophobicity which is the ten-
dency of nonpolar substances to repel water. This property
as noted by He et al., (2024) can be useful in separating
materials that have varying levels of resistance to water. For
instance, a material with high hydrophobicity will separate
more readily from a water-based solution than a material
with low hydrophobicity.
Density is another property which by using different
techniques, materials with higher densities can be separated
from those with lower densities. This technique can be used
to separate NMC cathode material from LMO cathode
materials as well as some of the newer cathode chemistries.
Magnetic susceptibility is another property as observed
by Ji et al., (2021) that plays a crucial role in the separation
process. It is a measure of how much a material will become
magnetized in an applied magnetic field. By manipulating
the magnetic field, materials with different magnetic sus-
ceptibilities can be effectively separated. This can be used
to separate aluminium and copper from the lithium based
cathode materials.
It is important to note that these techniques are not
used in isolation. Often, a combination of them is employed
to achieve the most efficient separation and recovery of
the electrode materials. Therefore, the process of electrode
separation and recovery is a complex yet essential aspect of
Direct Recycling. It necessitates a deep understanding of
the properties of the materials involved and the techniques
needed to exploit these properties effectively.
Binder Removal Process
A critical and complex task in the direct recycling of LIBs,
is to figure out the most effective and efficient method to
remove the binder. The binder plays a key role in hold-
ing together the electrode particles, which are a crucial
component in electronic devices. The challenge lies in
ensuring that the removal of this binder does not cause
significant damage to the performance abilities of these
particles.
The method should be designed in such a way that it
does not compromise the structural integrity of the par-
ticles, as they are essential to the overall functioning of the
electronic device. The binder, while crucial during the ini-
tial assembly of the device, becomes a hindrance during the
recycling process. Its removal is, therefore, a necessary step
to ensure the successful recovery of valuable materials from
the device.
The goal of the binder removal process is to minimize
the need for costly and time consuming post treatment
procedures. If the binder can be removed efficiently and
without causing significant damage to the particles, it elim-
inates the need for additional treatment processes, thereby
improving the overall efficiency and cost effectiveness of
direct recycling.
Some examples of binder removal as proposed by
Gaines et al., (2021) are by dissolving in n-methyl-2-pyr-
rolidone (NMP) but doing so is not cost effective or ther-
mal decomposition as this has the advantage of producing
no liquid waste and can be performed at temperatures as
low as 500°C. The key is slow ramping of the temperature
plus the addition of a small amount of excess lithium to
prevent lithium removal from the remaining materials.
Cathode Relithiation
This process aims to develop an energy efficient method for
the direct regeneration of cycled, degraded cathode active
particles. These particles are essential components of lith-
ium-ion batteries and are known as Lithium Cobalt Oxide
(LCO), Lithium Manganese Oxide (LMO), Nickel Cobalt
Manganese (NCM), Nickel Cobalt Aluminum (NCA),
and their various mixtures.
Over time and through the process of discharging and
recharging, these cathode active particles degrade and lose
their ability to deliver high electrochemical performance.
This decrease in performance can lead to a reduction in the
battery’s overall energy output and efficiency.
The goal of cathode relithiation is to directly regener-
ate these degraded particles in an energy-efficient manner.
This process would not only revive the high electrochemical
performance of these particles but also potentially increase
the overall lifespan of the battery in which they are used.
Relithiation as described by Pražanová et al., (2024)
involves introducing fresh lithium ions into the degraded
cathode active particles. These new ions can replace the ones
lost due to degradation and can restore the electrochemical
The recovery of the electrolyte would appear from
literature to be problematic and best treated via calcina-
tion at 1000°C or lower temperature evaporation while
drying other components. observed It is worth noting (
Hantanasirisakul, K &Sawangphruk, M, 2023) that cur-
rently electrolyte material is being recovered to comply
with US and EU environmental regulations rather than
for economic reasons. The key focus for future electrolyte
development is that it should be safe, green and sustainable.
Electrode Separation and Recovery
The process of electrode separation and recovery is a crucial
aspect of the Direct Recycling method. It involves the sepa-
ration and subsequent recuperation of mixtures of electrode
materials. The techniques used in this process are tailored
to uniquely leverage the specific properties of each material.
One such property is hydrophobicity which is the ten-
dency of nonpolar substances to repel water. This property
as noted by He et al., (2024) can be useful in separating
materials that have varying levels of resistance to water. For
instance, a material with high hydrophobicity will separate
more readily from a water-based solution than a material
with low hydrophobicity.
Density is another property which by using different
techniques, materials with higher densities can be separated
from those with lower densities. This technique can be used
to separate NMC cathode material from LMO cathode
materials as well as some of the newer cathode chemistries.
Magnetic susceptibility is another property as observed
by Ji et al., (2021) that plays a crucial role in the separation
process. It is a measure of how much a material will become
magnetized in an applied magnetic field. By manipulating
the magnetic field, materials with different magnetic sus-
ceptibilities can be effectively separated. This can be used
to separate aluminium and copper from the lithium based
cathode materials.
It is important to note that these techniques are not
used in isolation. Often, a combination of them is employed
to achieve the most efficient separation and recovery of
the electrode materials. Therefore, the process of electrode
separation and recovery is a complex yet essential aspect of
Direct Recycling. It necessitates a deep understanding of
the properties of the materials involved and the techniques
needed to exploit these properties effectively.
Binder Removal Process
A critical and complex task in the direct recycling of LIBs,
is to figure out the most effective and efficient method to
remove the binder. The binder plays a key role in hold-
ing together the electrode particles, which are a crucial
component in electronic devices. The challenge lies in
ensuring that the removal of this binder does not cause
significant damage to the performance abilities of these
particles.
The method should be designed in such a way that it
does not compromise the structural integrity of the par-
ticles, as they are essential to the overall functioning of the
electronic device. The binder, while crucial during the ini-
tial assembly of the device, becomes a hindrance during the
recycling process. Its removal is, therefore, a necessary step
to ensure the successful recovery of valuable materials from
the device.
The goal of the binder removal process is to minimize
the need for costly and time consuming post treatment
procedures. If the binder can be removed efficiently and
without causing significant damage to the particles, it elim-
inates the need for additional treatment processes, thereby
improving the overall efficiency and cost effectiveness of
direct recycling.
Some examples of binder removal as proposed by
Gaines et al., (2021) are by dissolving in n-methyl-2-pyr-
rolidone (NMP) but doing so is not cost effective or ther-
mal decomposition as this has the advantage of producing
no liquid waste and can be performed at temperatures as
low as 500°C. The key is slow ramping of the temperature
plus the addition of a small amount of excess lithium to
prevent lithium removal from the remaining materials.
Cathode Relithiation
This process aims to develop an energy efficient method for
the direct regeneration of cycled, degraded cathode active
particles. These particles are essential components of lith-
ium-ion batteries and are known as Lithium Cobalt Oxide
(LCO), Lithium Manganese Oxide (LMO), Nickel Cobalt
Manganese (NCM), Nickel Cobalt Aluminum (NCA),
and their various mixtures.
Over time and through the process of discharging and
recharging, these cathode active particles degrade and lose
their ability to deliver high electrochemical performance.
This decrease in performance can lead to a reduction in the
battery’s overall energy output and efficiency.
The goal of cathode relithiation is to directly regener-
ate these degraded particles in an energy-efficient manner.
This process would not only revive the high electrochemical
performance of these particles but also potentially increase
the overall lifespan of the battery in which they are used.
Relithiation as described by Pražanová et al., (2024)
involves introducing fresh lithium ions into the degraded
cathode active particles. These new ions can replace the ones
lost due to degradation and can restore the electrochemical