Project 4-1

Specific recycling process chains for lithium-ion batteries are developed at IFAD when dealing with different cell chemistries. Different process routes have been investigated for individual cell chemistries including mechanical processing, thermal treatment, flotation, hydrometallurgical separation and refining. However, a mixed input of different cell chemistries generates new challenges. An optimized, highly flexible process chain with the potential to react to changing input, generating stable qualities of battery-grade products will be necessary.

Specific objectives:

• Optimizing thermal pretreatment of mechanical processed lithium-ion battery cells/black mass in interaction with following process steps for mixtures of battery types
• Separation of electrode materials by flotation depending on the black mass composition
• Hydrometallurgical purification of the graphite concentrate and separation of the cathode as well as electrolyte materials into single metal preconcentrates
• Refining of single metal preconcentrates depending on black mass compositions
• Evaluation of potential splits and branching points within the hydrometallurgical process chain for changing, discontinuous or fluctuating cell type/black mass mixtures

Expected outcome:

• Developed resilient process chain for application on mixed/fluctuating lithium-ion battery cell input
• Design and evaluation of a flexible plant setup including splits and branching points of process streams
• Determination of the most relevant parameters for steering and control of such a system