Single-stage and multi-stage systems and methods for the recovery of critical elements in substantially pure form from lithium ion batteries are provided. The systems and methods include supported membrane solvent extraction using an immobilized organic phase within the pores of permeable hollow fibers. The permeable hollow fibers are contacted by a feed solution on one side, and a strip solution on another side, to provide the simultaneous extraction and stripping of elements from dissolved lithium ion cathode materials, while rejecting other elements from the feed solution. The single- and multi-stage systems and methods can selectively recover cobalt, manganese, nickel, lithium, aluminum and other elements from spent battery cathodes and are not limited by equilibrium constraints as compared to traditional solvent extraction processes.

A method for recovering at least cobalt of valuable metals, cobalt and nickel, from an acidic solution obtained by subjecting waste containing positive electrode materials for lithium ion secondary batteries to a wet process, the acidic solution comprising cobalt ions, nickel ions and impurities, the method including: a first extraction step for Co recovery, the first extraction step being for extracting cobalt ions by solvent extraction from the acidic solution and stripping the cobalt ions; and a second extraction step for Co recovery, the second extraction step being for extracting cobalt ions by solvent extraction from a stripped solution obtained in the first extraction step for Co recovery and stripping the cobalt ions, wherein the first extraction step for Co recovery includes: a solvent extraction process for extracting cobalt ions in the acidic solution into a solvent; a scrubbing process for scrubbing the solvent that has extracted the cobalt ions; and a stripping process for stripping the cobalt ions in the solvent after the scrubbing into a solution.

Processes and systems for recovering metals from a lithium-ion battery waste stream include optionally conducting a leaching process to form a leachate stream, purifying the leachate stream in a first reactor to remove fluorine (F), phosphate (P), and one or more impurity metals selected from the group consisting of: copper (Cu), aluminum (Al), iron (Fe), and titanium (Ti), separating nickel (Ni), manganese (Mn), and cobalt (Co) from the purified filtrate liquid stream by passing the purified filtrate liquid stream into (i) a reactor for conducting a co-precipitation process by increasing pH or (ii) one or more chromatographic columns to generate an intermediate liquid stream comprising lithium (Li) and one or more recovered products comprising one or more of nickel (Ni), manganese (Mn), and cobalt (Co). The intermediate liquid stream can be introduced into a lithium precipitation reactor to precipitate at least one compound comprising lithium (Li).

Processes and systems for recovering metals from a lithium-ion battery waste stream include optionally conducting a leaching process to form a leachate stream, purifying the leachate stream in a first reactor to remove fluorine (F), phosphate (P), and one or more impurity metals selected from the group consisting of: copper (Cu), aluminum (Al), iron (Fe), and titanium (Ti), separating nickel (Ni), manganese (Mn), and cobalt (Co) from the purified filtrate liquid stream by passing the purified filtrate liquid stream into (i) a reactor for conducting a co-precipitation process by increasing pH or (ii) one or more chromatographic columns to generate an intermediate liquid stream comprising lithium (Li) and one or more recovered products comprising one or more of nickel (Ni), manganese (Mn), and cobalt (Co). The intermediate liquid stream can be introduced into a lithium precipitation reactor to precipitate at least one compound comprising lithium (Li).

A method for recycling nickel, cobalt and manganese from a feed liquid containing nickel, cobalt and manganese, the method comprising: (1) subjecting the feed liquid to a first extraction to obtain an aqueous phase 1 and an organic phase 1; (2) subjecting the aqueous phase 1 to a second extraction to obtain an organic phase 2 and an aqueous phase 2 having a pH value of 5-7.5; and (3) successively subjecting the organic phase 2 to washing and reverse extraction to obtain a solution containing nickel, cobalt and manganese, wherein an extractant A used in the second extraction comprises a carboxylic acid extractant.

A method for recycling nickel, cobalt and manganese from a feed liquid containing nickel, cobalt and manganese, the method comprising: (1) subjecting the feed liquid to a first extraction to obtain an aqueous phase 1 and an organic phase 1; (2) subjecting the aqueous phase 1 to a second extraction to obtain an organic phase 2 and an aqueous phase 2 having a pH value of 5-7.5; and (3) successively subjecting the organic phase 2 to washing and reverse extraction to obtain a solution containing nickel, cobalt and manganese, wherein an extractant A used in the second extraction comprises a carboxylic acid extractant.

Single-stage and multi-stage systems and methods for the recovery of critical elements in substantially pure form from lithium ion batteries are provided. The systems and methods include supported membrane solvent extraction using an immobilized organic phase within the pores of permeable hollow fibers. The permeable hollow fibers are contacted by a feed solution on one side, and a strip solution on another side, to provide the simultaneous extraction and stripping of elements from dissolved lithium ion cathode materials, while rejecting other elements from the feed solution. The single- and multi-stage systems and methods can selectively recover cobalt, manganese, nickel, lithium, aluminum and other elements from spent battery cathodes and are not limited by equilibrium constraints as compared to traditional solvent extraction processes.

Provided are processes for extracting lithium and optionally nickel from a Nickel(II)/Lithium(I) (Ni.sup.2+/Li.sup.+) solution. The extraction is optionally performed in a series of steps with counterflow of aqueous and organic flows to thereby produce a lithium poor solution. The lithium poor solution may be treated so that remaining Ni in the lithium poor solution may be directly precipitated therefrom in the form of a Ni salt. Once complete, the process provides for recoverable nickel and/or lithium that may be recycled into batteries or sold for other uses.

Provided are processes for extracting lithium and optionally nickel from a Nickel(II)/Lithium(I) (Ni.sup.2+/Li.sup.+) solution. The extraction is optionally performed in a series of steps with counterflow of aqueous and organic flows to thereby produce a lithium poor solution. The lithium poor solution may be treated so that remaining Ni in the lithium poor solution may be directly precipitated therefrom in the form of a Ni salt. Once complete, the process provides for recoverable nickel and/or lithium that may be recycled into batteries or sold for other uses.

A method of processing copper and nickel sulfide materials, including oxidizing torrefaction of a material to obtain cinder, leaching the cinder with a cycling solution, separating a leaching residue, and electro-extraction of copper from a leaching solution. The cinder and particulates generated by the torrefaction are separately leached. The particulates are leached in a cycling copper raffinate together with a separated portion of solution from a cinder processing line, the separated portion consisting of a portion of solution provided to the leaching after electro-extraction of copper. Particulates leaching residue is separated. Copper is extracted by solvent extraction from a particulates leaching solution, followed by separate electro-extraction of copper from a circulating re-extract. Then, a portion of the raffinate is separated to be forwarded to a nickel production process.