A manganese-lithium separation process and a pre-extraction solution preparation process in comprehensive recovery of ternary battery wastes, and a method for comprehensive recovery of cobalt, nickel, manganese and lithium elements from the ternary battery wastes, relates to a method for recycling battery wastes. According to the present disclosure, cobalt and nickel ions are separated from an impurity-removed solution by a hydrolysis method; manganese, lithium and other ions in the impurity-removed solution are free from an extraction procedure, so that most manganese ions are separated and removed by a wet method before extraction, to prevent the manganese ions from entering the extraction system; nickel ions are free from an extraction procedure of full extraction and full back-extraction; and nickel hydroxide is directly precipitated after related impurities are removed by extraction.

A process for recovering materials from a black mass material obtained from lithium-ion batteries can include: i) conveying a black mass material as a black mass solid stream; ii) leaching the black mass solid stream to form a pregnant leach solution and residual solids; iii) separating the pregnant leach solution from the residual solids; iv) isolating a copper product from the pregnant leach solution; v) isolating an aluminum (Al) and/or iron (Fe) product from the pregnant leach solution; vi) isolating a manganese (Mn) product from the from the pregnant leach solution; vii) isolating a cobalt (Co) product from the from the pregnant leach solution; viii) isolating a nickel (Ni) product from the from the pregnant leach solution; ix) isolating a salt by-product from the pregnant leach solution; and x) isolating a lithium product the pregnant leach solution.

A process for recovering materials from a black mass material obtained from lithium-ion batteries can include: i) conveying a black mass material as a black mass solid stream; ii) leaching the black mass solid stream to form a pregnant leach solution and residual solids; iii) separating the pregnant leach solution from the residual solids; iv) isolating a copper product from the pregnant leach solution; v) isolating an aluminum (Al) and/or iron (Fe) product from the pregnant leach solution; vi) isolating a manganese (Mn) product from the from the pregnant leach solution; vii) isolating a cobalt (Co) product from the from the pregnant leach solution; viii) isolating a nickel (Ni) product from the from the pregnant leach solution; ix) isolating a salt by-product from the pregnant leach solution; and x) isolating a lithium product the pregnant leach solution.

Disclosed is a method for removing aluminum in a ternary battery material leachate by adopting an extraction method, which comprises the following steps: (1) saponification: mixing an extraction solvent with a saponifying agent to obtain a saponified extraction solvent; (2) extraction: mixing the ternary battery material leachate with the saponified extraction solvent to obtain a loaded organic phase and a raffinate; (3) back extraction: mixing the loaded organic phase with a back-extraction agent, followed by performing a back-extraction to obtain an organic phase and a back-extraction solution; the extraction solvent comprises an extracting agent and a diluent. The extraction method is adopted to separate nickel, cobalt, manganese and aluminum, having the advantages of less heavy metal entrainment, short process flow, and high metal recovery rate. The extraction rate of the aluminum can reach 97.42 percent.

Disclosed is a method for removing aluminum in a ternary battery material leachate by adopting an extraction method, which comprises the following steps: (1) saponification: mixing an extraction solvent with a saponifying agent to obtain a saponified extraction solvent; (2) extraction: mixing the ternary battery material leachate with the saponified extraction solvent to obtain a loaded organic phase and a raffinate; (3) back extraction: mixing the loaded organic phase with a back-extraction agent, followed by performing a back-extraction to obtain an organic phase and a back-extraction solution; the extraction solvent comprises an extracting agent and a diluent. The extraction method is adopted to separate nickel, cobalt, manganese and aluminum, having the advantages of less heavy metal entrainment, short process flow, and high metal recovery rate. The extraction rate of the aluminum can reach 97.42 percent.

A process for removal of aluminium and iron in the recycling of rechargeable batteries comprising providing a leachate from black mass, adding phosphoric acid (H.sub.3PO.sub.4) to said leachate and adjusting the pH to form iron phosphate (FePO.sub.4) and aluminium phosphate (AlPO.sub.4), precipitating and removing the formed FePO.sub.4 and AlPO.sub.4, and forming a filtrate for further recovery of cathode metals, mainly NMC-metals and lithium.

A process for removal of aluminium and iron in the recycling of rechargeable batteries comprising providing a leachate from black mass, adding phosphoric acid (H.sub.3PO.sub.4) to said leachate and adjusting the pH to form iron phosphate (FePO.sub.4) and aluminium phosphate (AlPO.sub.4), precipitating and removing the formed FePO.sub.4 and AlPO.sub.4, and forming a filtrate for further recovery of cathode metals, mainly NMC-metals and lithium.

Process for the recovery of transition metal from cathode active materials containing nickel and lithium, wherein said process comprises the steps of (a) treating a lithium containing transition metal oxide material with a leaching agent (preferably an acid selected from sulfuric acid, hydrochloric acid, nitric acid, methanesulfonic acid, oxalic acid and citric acid), (b) adjusting the pH value to 2.5 to 8, and (c) treating the solution obtained in step (b)with metallic nickel, cobalt or manganese or a combination of at least two of the foregoing.

Process for the recovery of transition metal from cathode active materials containing nickel and lithium, wherein said process comprises the steps of (a) treating a lithium containing transition metal oxide material with a leaching agent (preferably an acid selected from sulfuric acid, hydrochloric acid, nitric acid, methanesulfonic acid, oxalic acid and citric acid), (b) adjusting the pH value to 2.5 to 8, and (c) treating the solution obtained in step (b)with metallic nickel, cobalt or manganese or a combination of at least two of the foregoing.

A process for recovering a nickel cobalt manganese hydroxide from recycled lithium-ion battery (LIB) material such as black mass, black powder, filter cake, or the like. The recycled LIB material is mixed with water and either sulfuric acid or hydrochloric acid at a pH less than 2. Cobalt, nickel, and manganese oxides from the recycled lithium-ion battery material dissolve into the acidic water with the reductive assistance of gaseous sulfur dioxide. Anode carbon is filtered from the acidic water, leaving the dissolved cobalt, nickel, and manganese oxides in a filtrate. The filtrate is mixed with aqueous sodium hydroxide at a pH greater than 8. Nickel cobalt manganese hydroxide precipitates from the filtrate. The nickel cobalt manganese hydroxide is filtered from the filtrate and dried. The filtrate may be treated ammonium fluoride or ammonium bifluoride to precipitate lithium fluoride from the filtrate. The composition ratio of nickel to cobalt to manganese in the acid filtrate may be adjusted to a desired ratio. The anode carbon is recovered and purified for reuse.