We will present on a novel and environment-friendly process for extracting lithium, graphite and cobalt from lithium-ion batteries. The process integrates electrochemical concentration of lithium during fast charging and subsequent elemental recovery using only water as the solvent. By recovering the critical elements in lithium-ion batteries via simple but efficient process, we reveal a paradigm shift from the current multi-step and complex processes. Our concept possesses both environmental and economic advantages, wherein lithium, highly pyrolytic graphite and cobalt can be recovered from end-of-life lithium-ion batteries using only water, without the requirement of additional acids and toxic solvents.

Lithium-based batteries represent ~37% of the rechargeable battery market with the highest product life and nearly 100% cycling efficiency, compared to other energy storage solutions. With the worldwide massive adoption of lithium-ion batteries, the demand is projected to increase by 150% in five years. This expected exponential increase in consumption of lithium-ion batteries would pose a unique challenge to the availability of critical resources like lithium, graphite and transition metals like cobalt, in the upcoming decade. The important role of recycling in ensuring sustainability in supply of battery materials is normally acknowledged but only small amount of the used batteries are recycled in the U.S.. There is a need for environmentally safe processes with ability to recover and reintroduce the critical elements as high-quality battery-grade products at competitive prices, compared to naturally sourced raw materials.

The process is environmentally safe. We have demonstrated ~92% lithium recovery as salts, ~97% graphite recovery after heat treatment and ~92% cobalt oxide recovery from lithium pouch cells.

Extracted lithium salt gravimetric analysis vs. C-rate, a) Anode, and b) Cathode.

Anirudha Karati

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