STREAMLINED LITHIUM-ION BATTERY WASTE RECYCLING

Abstract

A process for recovering and purifying nickel (Ni), manganese (Mn), cobalt (Co), and lithium (Li) from black mass obtained from recycling of lithium-ion batteries to produce high purity products. The process may include reductive acid leaching, impurity removal, precipitation of valuable metals such as Ni, Co, Mn, and Li. The process may also include recycling of Li compounds as hydroxide or carbonate as a source of alkaline reagent for impurity removal and/or precipitation of the valuable metals.

Claims

1. A method of recovering lithium-ion battery materials from black mass, wherein the method comprises: acid leaching the black mass in a first stage to produce acid-leached material; and subsequently, applying a reducing agent to the acid-leached material in a second stage.

2. The method of claim 1, wherein the reducing agent includes hydrogen peroxide (H.sub.2O.sub.2).

3. The method of claim 1, wherein the black mass may include copper (Cu) and aluminum (Al) impurities, and wherein the copper and aluminum impurities can act as reducing agents in the first stage.

4. The method of claim 1, wherein the first stage is performed at a first temperature and the second stage is performed at a second temperature, and the second temperature is lower than the first temperature.

5. The method of claim 1, wherein valuable metals recovered by the method include one or more of nickel (Ni), manganese (Mn), cobalt (Co), and lithium (Li).

6. A method of recovering valuable metals from black mass, wherein the method comprises: performing upstream processes on the black mass; and using a Li basic solution as a reagent in one or more of the upstream processes.

7. The method of claim 6, wherein the upstream processes include one or more of impurity removal by chemical precipitation, impurity removal by ion exchange, and mixed or co-precipitation.

8. The method of claim 6, further comprising an impurity removal step, and wherein the use of the Li basic solution reduces loss of one or more of Ni, Mn, Co, and Li during the impurity removal step.

9. The method of claim 6, wherein the Li basic solution includes an impure solution of lithium hydroxide (LiOH).

10. The method of claim 6, wherein the Li basic solution includes an impure solution of lithium carbonate (Li.sub.2CO.sub.3).

11. A process for recovering and purifying valuable metals from black mass obtained from recycling of lithium-ion batteries, wherein the valuable metals include one or more of Ni, Mn, Co, and Li, and wherein the process comprises: (a) leaching the black mass to form an acid leached slurry including an acidic pregnant leach solution (PLS) containing the valuable metals and impurities, and an insoluble material; (b) separating the acidic PLS and the insoluble material; (c) adjusting the pH of the acidic PLS for impurity removal to form a pH-adjusted slurry including an impurity precipitate containing the impurities and a pH-adjusted PLS containing the one or more of Ni, Mn, Co, and Li; (d) separating the pH-adjusted PLS and the impurity precipitate; (e) removing residual impurities from the pH-adjusted PLS by adsorption using an ion exchange resin to form a purified PLS containing the valuable metals, wherein the removing includes eluting the adsorbed impurities from the ion-exchange resin using an eluent and regenerating the ion-exchange resin; (f) adjusting the pH of the purified PLS containing the valuable metals using a Li basic solution to form the mixed precipitate slurry, wherein the concentrations of the valuable metals may be adjusted according to the ratio required for a product by adding corresponding sulfates; (g) separating the mixed precipitate containing the valuable metals and a solution containing Li; (h) processing the solution containing Li to produce a basic solution for use in at least one of steps (c), (e), and/or (f); and (i) recovering Li as high-purity Li.sub.2CO.sub.3 or high-purity LiOH.

12. The process of claim 11 wherein the black mass includes the valuable metals, graphite, and at least one of iron (Fe), Al, and Cu.

13. The process of claim 11 wherein the leaching includes a two-stage leaching process including acid leaching with an acid at suitable conditions and reductive leaching with a reducing agent at suitable conditions.

14. The process of claim 13 in which the acid includes sulfuric acid and the reducing agent includes hydrogen peroxide (H.sub.2O.sub.2).

15. The process of claim 11 in which the reagent for adjusting the pH includes the Li basic solution.

16. The process of claim 11 in which the reagent for regenerating the ion exchange resin includes the Li basic solution.

17. The process of claim 11 in which the reagent for mixed precipitation includes the Li basic solution.

18. The process of claim 15, wherein the Li basic solution includes an impure solution of LiOH.

19. The process of claim 16, wherein the Li basic solution includes an impure solution of LiOH.

20. The process of claim 17, wherein the Li basic solution includes an impure solution of LiOH.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0026] FIG. 1 is a process flow diagram for a streamlined hydrometallurgical advanced recycling process (SHARP) performed in accordance with the present disclosure;

[0027] FIG. 2 includes graphs showing precipitation of metals at different pH using NaOH and Li basic solution; and

[0028] FIG. 3 is a comparative process flow diagram showing pyrometallurgical and hydrometallurgical methods and a method of processing black mass in accordance with the present disclosure.

DETAILED DESCRIPTION

[0029] Referring now to the drawings, where like reference numerals designate like elements, the present disclosure relates to a process for recovering and purifying Ni, Mn, Co, and Li from black mass 10 (FIG. 1) for use in producing high purity products. If desired, the black mass 10 may be obtained from recycling of LiB waste.

[0030] In the example illustrated in FIG. 1, the process includes: (i) acid leaching black mass (S100) to form an acidic pregnant leach solution (PLS) containing valuable metals such as Ni, Mn, Co, and Li, and impurities, and an insoluble material, where the leaching process (S100) is a two-stage process including (a) acid leaching (S102) with an acid at suitable conditions and (b) reductive leaching (S104) with a reducing agent at suitable conditions; (ii) separating (S106) the acidic PLS 12 and the insoluble material or acid-leached residue 14; (iii) adjusting (S108) the pH of the acidic PLS 12 using a Li basic solution 16 to form a pH-adjusted slurry 18 including an impurity precipitate containing impurities and a pH-adjusted PLS containing valuable metals such as Ni, Mn, Co, and Li; and (iv) separating (S110) the pH adjusted PLS 20 and the impurity precipitate 22.

[0031] Further, the process illustrated in FIG. 1 includes: (v) removing (S112) any residual impurities from the pH adjusted PLS 20 by adsorption using an ion exchange resin to form the purified PLS containing valuable metals such as Ni, Mn, Co, and Li, where the removing step (S112) includes (a) eluting the adsorbed impurities from the ion-exchange resin using appropriate eluents and (b) regenerating the ion-exchange resin using the Li basic solution 16; (vi) adjusting (S114) the pH of the purified PLS containing valuable metals such as Ni, Mn, Co, and Li using the Li basic solution 16 to form a mixed precipitate slurry; (vii) separating (S116) the mixed precipitate containing Ni, Mn, and Co, and a solution containing Li, where the mixed precipitate 24 can be of high purity (up to battery-grade purity) for use as a precursor cathode active material; and (viii) processing (S118) the solution containing Li to produce the Li basic solution 16 for use in steps (iii), (v), and (vi) (or in at least one of steps (iii), (v), and (vi)), where the Li basic solution 16 is impure LiOH or Li.sub.2CO.sub.3 solution.

[0032] The feedstock to the process (that is, the black mass 10) may be a mixture of cathode and anode materials from recycling of LiB waste or scraps. If desired, the LiB waste or scraps may include at least one of the LiB chemistries lithium iron phosphate (LFP), lithium cobalt oxide (LCO), lithium manganese oxide (LMO), lithium nickel manganese cobalt oxide (NMC), lithium nickel cobalt aluminum oxide (NCA), and lithium titanate (LTO). Further, the black mass 10 may include least one of the valuable metals Ni, Co, Mn, and Li, graphite (C), and at least one impurity such as iron (Fe), aluminum (Al), copper (Cu), phosphorous (P), calcium (Ca), magnesium (Mg), fluoride (F), zirconium (Zr), zinc (Zn), and rare earth elements (REE).

[0033] According to one aspect of the present disclosure, the leaching process (S100) is performed in two stages (S102, S104) to efficiently utilize the reducing power of Al and/or Cu metals and prevent overconsumption of H.sub.2O.sub.2. Firstly, the feedstock is mixed with acidic solution (S102) to dissolve at least a portion of Ni, Mn, Co, Li, and impurities. Suitable acids may include, but are not limited to, mineral acids including sulfuric acid, hydrochloric acid, and nitric acid. The amount of acid to be added may be more than the stoichiometric amount required to completely dissolve the Ni, Mn, Co, and Li, and impurities. The leaching may be carried out at a temperature equal to or less than the boiling point of the slurry, while the slurry is thoroughly mixed. A portion of at least one Ni, Mn, Co, and Li is dissolved in solution. The relatively low leaching efficiency of particularly Co and Mn are due to the formation of higher valence state species, such as Co.sup.3+ and Mn.sup.4+, during the charging-discharging cycle of the battery. Based on the Eh-pH solution chemistry of the metals, dissolution of higher valence states is lower relative to their lower valence states (Co.sup.2+ and Mn.sup.2+). Ni and, to some extent, Li are closely associated with Co and Mn; hence, their leaching efficiencies are affected by lower Co and Mn dissolution.

[0034] Then (after S102), the acidic slurry from the first stage of acid leaching may be cooled to a temperature suitable for an efficient reaction with the reducing agent (S104), preferably about 60-70° C. to reduce the rate of H.sub.2O.sub.2 decomposition. The reducing agent may include, but is not limited to, H.sub.2O.sub.2, sulfur dioxide, sodium bisulfite, or sodium metabisulfite. The amount of the reducing agent may be more than the stoichiometric amount required to reduce the oxidized valuable metals particularly Co.sup.3+ to Co.sup.2+ and Mn.sup.4+ to Mn.sup.2+ while the solution is thoroughly mixed. Any undissolved valuable metals and impurities may be partially present in the insoluble material. Separation (S106) of the acidic PLS and the insoluble material 14 may be accomplished by known methods such as gravitational settling, decantation, filtration, centrifugation, or any other appropriate method.

[0035] The insoluble material 14 may contain graphite and may be further purified and regenerated to form a saleable (marketable) product or reused in the process as adsorber for organics.

[0036] In operation, the acidic PLS containing Ni, Mn, Co, and Li, and impurities may be added with a suitable alkali reagent to precipitate at least a portion of one or more impurities including, but not limited to, Al, Cu, Fe, P, and Zr. Li basic solution 16 can be preferentially used to reduce the introduction of impurities that could occur when using other alkali reagents such as NaOH, Na.sub.2CO.sub.3, calcium hydroxide, potassium carbonate (K.sub.2CO.sub.3), potassium hydroxide (KOH) or costly reagents such as Li.sub.2CO.sub.3, or LiOH. The pH-adjusted slurry 18 that is formed includes an impurity precipitate 22 and a pH-adjusted PLS 20 containing Ni, Mn, Co, and Li, and residual impurities which may be separated by suitable methods such as gravitational settling, decantation, filtration, centrifugation, or any other appropriate method.

[0037] If desired, the residual impurities in the pH-adjusted PLS 20 may be removed by ion exchange (S112) using a suitable ion exchange resin. The removal of residual impurities, particularly Al and Cu, from the pH-adjusted PLS may be completed without significant co-adsorption of Ni, Mn, Co, and Li. The adsorbed impurities may be eluted from the resin by suitable eluents. The eluted resin may be regenerated by an alkali reagent in solution form. The regenerant can be the Li basic solution 16 containing Li from the process to reduce introduction of new impurities to the solution. The regenerated resin may be reused.

[0038] The recovery of valuable metals such as Ni, Mn, and Co from the purified PLS may be performed by adjusting the pH using an alkali reagent. The alkali reagent may be Li basic solution 16 to reduce the introduction of impurities that would have been introduced at high levels by using other basic reagents such as Na.sub.2CO.sub.3, K.sub.2CO.sub.3, NaOH, or KOH or by using other alkali reagents such as Li.sub.2CO.sub.3, or LiOH that are costly. When an alkali carbonate is used, the pH of precipitation may be at least 6 and up to 9, or at least 6.5 and up to 8.5, or at least 7 up to 8, whereas when an alkali hydroxide is used, the pH of precipitation may be at least 7 and up to 13, or at least 10.5 and up to 12.5, or at least 11 and up to 12.

[0039] If desired, the precipitation (S114) may be carried out at a temperature equal to or less than the boiling point of the slurry while the slurry is thoroughly mixed. The mixed or co-precipitation process may be in batch or continuous mode. Optionally, the precipitation may employ a co-precipitation process using a chelating agent such as ammonium hydroxide. The mixed precipitate slurry that is formed includes a mixed precipitate 24 containing Ni, Mn, and Co, and a solution containing Li, which can be separated by suitable methods (S116) such as gravitational settling, decantation, filtration, centrifugation, or any other appropriate method.

[0040] The solution containing Li may be further processed (S118) to recover Li basic solution 16 to be used as a reagent for at least one of the frontend processes illustrated in FIG. 1, including one or more of the following: (i) converting (S122) a portion of the concentrated Li solution into Li.sub.2CO.sub.3 by reacting stoichiometrically with Na.sub.2CO.sub.3, if production of Li.sub.2CO.sub.3 as Li basic solution or final product is intended; (ii) further purifying the generated Li.sub.2CO.sub.3 28 if it is intended to be used as a final product for industrial or battery-grade applications; (iii) converting a portion of the concentrated Li solution into a solution of LiOH and sodium sulfate (Na.sub.2SO.sub.4) by metathetically reacting with NaOH (S120); (iv) crystallizing Na.sub.2SO.sub.4 through evaporative crystallization or cooling crystallization (S120); (v) separating the crystallized Na.sub.2SO.sub.4 26 and the mother liquor containing LiOH and soluble Na.sub.2SO.sub.4 by suitable methods such as gravitational settling, decantation, filtration, centrifugation, or any other appropriate methods, where the mother liquor is the Li basic solution 16; and (vi) further purifying the generated LiOH if it is intended to be used as a final product for industrial or battery-grade applications.

[0041] The following examples (Comparative Tests 1 and 2) are illustrative of processes in accordance with the present disclosure:

[0042] Comparative Test 1: Two-Stage Leaching—Acid Leaching Followed by Reductive Leaching, Compared with Single-Stage Leaching where Acid Leaching and Reduction Take Place Simultaneously.

[0043] A black mass sample 1 having the composition shown in Table 1 was considered in the comparative leaching tests. The leaching was done in an 800-mL beaker using an overhead agitator and an electrically heated hotplate. The reagents used were analytical grade 98% wt H.sub.2SO.sub.4 from Merck and industrial grade 50% wt H.sub.2O.sub.2 solution. About 50 g of the black mass on dry basis was used in each test parameter employed. The amount of H.sub.2SO.sub.4 was 20% in excess of the stoichiometric requirement to form corresponding sulfates of Ni, Co, Mn, Li, Al, Cu, and Fe. The amount of H.sub.2O.sub.2 used was the same for each case.

[0044] For the two-stage leaching, the black mass was first leached in H.sub.2SO.sub.4 solution at 80-90° C. for 2 hours. A sample of the slurry was taken for analysis to determine the quantity of metals, particularly Co and Mn, left in the residue. The amount of H.sub.2O.sub.2 was calculated based on amount of residual Co and Mn. The acid-leached slurry was cooled to 55-65° C. in preparation for the reduction step. H.sub.2O.sub.2 was added into the slurry via a peristaltic pump at a rate of 1 mL/min.

[0045] For the one-stage leaching, the black mass was leached in a solution of H.sub.2SO.sub.4 and H.sub.2O.sub.2 at two different temperatures for 2 hours. The same amount of H.sub.2O.sub.2 as calculated in the two-stage leaching was used. A sample of the slurry was taken for analysis.

[0046] All samples were filtered using Whatman 41. The solutions and residues were prepared according to established procedures and analyzed using Agilent 5110 ICP-OES.

TABLE-US-00001 TABLE 1 Comparison between Two-Stage Leaching and One-Stage Leaching of Black Mass Sample 1 Extent of Leaching Two-Stage Leaching One-Stage One-Stage Black Stage 1 - Stage 2 - Reductive Reductive Mass Acid Reductive Acid Acid Compo- Leaching @ Leaching @ Leaching @ Leaching @ Metal sition 80-90° C. 55-65° C. 80-90° C. 55-65° C. Mn 11.5% 44% >99% 78% 75% Co 10.3% 86% >99% 81% 77% Ni 22.5% 87% >99% 83% 69% Li 5.8% 97% >99% 94% 90% Al 2.0% 98% >99% 98% 97% Cu 8.6% 90% >99% 96% 99% Fe 0.01% 57% >99% 99% 99%

[0047] The relatively low leaching efficiency of Co and Mn in Stage 1 is attributed to the presence of higher valence state species, including Co.sup.3+ and Mn.sup.4+, from the charging-discharging cycle of the battery. The solubility of these higher valence states is lower relative to their lower valence states (Co.sup.2+ and Mn.sup.2+). Ni and, to some extent, Li are closely associated with Co and Mn; hence, their leaching efficiencies can be affected. At the same time, Al, Cu, and Fe can be present in the black mass as metals, and their dissolution by the acid releases corresponding electrons that can reduce Co.sup.3+ and Mn.sup.4+, according to the half-cell reactions shown in Table 2.

TABLE-US-00002 TABLE 2 Reduction Potentials of Metals and Reducing Agent at 30 C. (V vs. SHE) Half-Cell Reaction Reduction potential, V Co.sup.3+ + e.sup.− .fwdarw. Co.sup.2+ 1.97 H.sub.2O.sub.2 + 2H.sup.+ + 2e.sup.− .fwdarw.2H.sub.2O 1.76 MnO.sub.2 + 4H.sup.+ + 2e.sup.− .fwdarw. Mn.sup.2+ + 2H.sub.2O 1.23 Fe.sup.3+ + e.sup.− .fwdarw. Fe.sup.2+ 0.77 O.sub.2 + H.sup.+ + e.sup.− .fwdarw. 2H.sub.2O.sub.2 0.69 Cu.sup.2+ + 2e.sup.− .fwdarw. Cu 0.34 Fe.sup.2+ + 2e.sup.− .fwdarw. Fe −0.44 Al.sup.3+ + 3e.sup.− .fwdarw. Al −1.68

[0048] Known leaching systems for black mass are performed in a single step, that is, the black mass is reacted with the mixture of the lixiviant and the reducing agent. Shown in Table 1, when one-step reductive acid leaching is done, the extent of leaching of particularly Co and Mn were lower at the same amount of H.sub.2O.sub.2 used in the two-stage leaching given the overall same amount of reaction time.

[0049] The one-step leaching system at 80-90° C. could have suffered either or both of the following causes of inefficient use of H.sub.2O.sub.2. With high temperature, the rate of decomposition of H.sub.2O.sub.2 is very fast. Also, H.sub.2O.sub.2 can act as both a reducing agent and an oxidizing agent in the leaching system. Having an oxidation potential above that of Al, Cu, and Fe (including Fe.sup.2+ which also holds a reductive power), it can rapidly react with and oxidize the metals. Therefore, when H.sub.2O.sub.2 is added in one step with the acid, the reductive power of the metals would not be utilized by Co.sup.3+ and Mn.sup.4+, which in turn can result in unnecessary over-consumption of H.sub.2O.sub.2. The latter cause could be more prevalent in one-step leaching systems at lower temperature.

[0050] Comparative Test 2: Impurity Removal by Chemical Precipitation Using NaOH and Li Basic Solution

[0051] An objective of the impurity removal via chemical precipitation step (see FIG. 1, S108) is to remove all the Fe and most of Al and Cu in one step without substantially precipitating any of the critical metals. Laboratory experiments were conducted to evaluate the behavior of the metals at different pH using NaOH and Li basic solution as neutralizing agents. About 150 mL of the PLS from the leaching of black mass sample 1 was added to the reagent at different pHs at ambient temperature. The acidic PLS contained 13,000 ppm Mn, 12,000 ppm Co, 23,000 ppm Ni, 6,000 ppm Li, 2,000 ppm Al, 7,000 ppm Cu, and 15 ppm Fe. A stabilization period of 30 minutes at the pH was allowed prior to taking a sample for analysis. The samples were filtered using Whatman 41 filter paper and analyzed using Agilent 5110 ICP-OES. The pH meter was a Thermo Scientific Orion Star A211 pH meter.

[0052] FIG. 2 shows the results of the tests conducted. Understandably, because the Fe concentration is very low in the PLS, the onset of its precipitation was found to be at pH 4 attaining complete precipitation at pH 4. With the relatively higher concentration of Al in the PLS, on the other hand, it almost approached complete precipitation at pH 4.5, with minimal co-precipitation of Co, Mn, and/or Ni. At full precipitation of Al, for example at pH 5.5, the co-precipitation of Co, Mn, and Ni when Li basic solution was used was significantly lower than when NaOH was used at the same pH. This means the residual Al and Cu in the PLS can be further minimized, which could lead to relatively longer breakthrough and exhaustion of the IX resin and ultimately lower frequency of elution, thus lower associated reagent cost. Also, Li remained in the solution all throughout the pH range tested as expected because Li as the hydroxide is very soluble. Further, as shown in FIG. 2, the complete precipitation of Al can happen between pH 4.5 and 5, while Cu precipitates at about pH 6. At full precipitation of Al, for example at pH 5.5, the co-precipitation of Co, Mn and Ni was significantly lower than when NaOH was used at the same pH. Again, Li remained in the solution throughout the pH range tested as expected because Li as the hydroxide is very soluble.

[0053] Comparative Test 3: Mixed Metal Precipitation Using NaOH and Li Basic Solution

[0054] An acidic PLS with total Ni, Mn, and Co concentrations [TM] of 1 molar obtained by leaching black mass sample 1 was prepared. The PLS was split into two parts. The first part went through impurity removal, and mixed precipitation steps using Li basic solution. The second part used NaOH. All parameters such as agitation, temperature, rate of addition, reaction time, and pH were the same for both tests.

[0055] The precipitates generated were washed with the same amount of deionized water. The washing was collected and measured for conductivity using Thermo Scientific Orion A Star Conductivity Meter and analyzed for Na and Li to monitor the extent of washing. The results are shown in Table 3.

TABLE-US-00003 TABLE 3 Mixed Precipitate Generated by using Li Basic Solution as Reagent PLS after Impurity PLS after Mixed Removal Precipitation Mixed Precipitate Reagent Na, gpL Li, gpL Na, gpL Li, gpL Na, ppm Li, ppm Li basic 13 13 20 15 37 87 solution

[0056] The required amount of water to wash the precipitate to reach the same level of Na impurity was significantly higher in the test where NaOH was used as a precipitating agent. It was estimated that by using Li basic solution, there would be at least 50% reduction in evaporation duty of wastewater. In effect, this also means relatively smaller equipment capacity requirement and lower energy consumption.

[0057] The results in Table 3 show that in the presence of a high concentration of Li, mixed Ni, Mn, and Co precipitate was produced with minimal amount of Li. A study by Jo, M. et al. (2018), “Effects of Residual Lithium in the precursors of Li[Ni.sub.1/3Co.sub.1/3Mn.sub.1/3]O.sub.2 on their lithium-ion battery performance,” reported the involuntary introduction of Li to the precursors during co-precipitation of Ni, Mn, and Co in the presence of Li in solution. Jo, M. et al. observed undesirable cation mixing with the increasing Li content of the precursors. The results in Table 3 show that inclusion of Li in the mixed precipitate can be minimal by applying parameters according to the present disclosure even in the presence of high concentration of Li. It is believed that by applying the process parameters of the present disclosure, almost all Li is adsorbed on the surface of particles rather than inserted into the crystal structure which can be removed by washing.

[0058] Test 4. Processing of Black Mass Sample 1

[0059] A process in accordance with the present disclosure was tested on a sample of black mass from acid leaching to mixed precipitation. About 225 g of the black mass sample 1 having the composition shown in Table 4 was leached via the above-described two-stage leaching (see FIG. 1, S100). After separating the insoluble materials, the PLS was then adjusted to pH 4.5-4.7 at 30-40° C. using the Li basic solution generated from a previous experiment. The resulting slurry was filtered to separate the pH-adjusted PLS and the impurity precipitate. The pH-adjusted PLS was then fed to an ion exchange column containing a suitable resin for adsorption of the residual Al and Cu. The raffinate, or the purified PLS, was adjusted with the Li basic solution to precipitate all the valuable metals Co, Mn, and Ni, which was at a pH of 11-11.5. The resulting slurry was filtered to separate the Li-containing solution from the mixed precipitate. The mixed precipitate was then washed and dried.

[0060] The Li-containing solution was processed to produce Li.sub.2CO.sub.3 and Li basic solution.

TABLE-US-00004 TABLE 4 Analysis of a black mass Sample 1 and resulting leachate, purified solution, and mixed metal precipitate Leachate Purified Mixed Compo- Black Mass (mixed metal mixed metal metal sition Sample 1 solution) solution precipitate Ni:Mn:Co 0.5:0.3:0.2 — — 0.5:0.3:0.2 Li 5.85% 8.9 gpL 12.7 gpL 0.01% Al 20,000 ppm 2,900 ppm <1 ppm <15 ppm Cu 86,000 ppm 11,400 ppm <1 ppm <5 ppm Fe 70 ppm 23.4 ppm <1 ppm <10 ppm Na 700 ppm 80 ppm 6,100 ppm <120 ppm

[0061] As shown in Table 4, the mixed metal precipitate produced in Test 4 has a similar composition as the infeed in terms of metal ratios. As a result, the mixed metal precipitate can be advantageously employed directly in the production of a cathode precursor. Fe, Al, and Cu concentrations in the purified solution and the mixed precipitate are low. The Na and Li contents are within an acceptable range according to known specifications. In these experiments, Ni, Mn, and Co concentrations were not adjusted. Alternatively, the concentrations can be adjusted to reach the desirable Ni:Mn:Co.

[0062] Test 5. Processing of Black Mass Sample 2

[0063] The same procedure as in Test 4 was employed in the processing of black mass sample 2. The results are shown in Table 5.

TABLE-US-00005 TABLE 5 Analysis of black mass Sample 2 and resulting leachate, purified solution, and mixed metal precipitate Leachate Purified Mixed (mixed metal mixed metal metal Composition Black mass solution) solution precipitate Ni:Mn:Co 0.5:0.2:0.2 — — 0.5:0.2:0.2 Li 4.50% 5 gpL 17.9 gpL 0.007% Al 4,000 ppm 400 ppm <1 ppm <20 ppm Cu 3,000 ppm 400 ppm <1 ppm <0.02 ppm Fe 5,000 ppm 600 ppm <1 ppm <0.02 ppm Na 800 ppm 2,000 ppm 2,000 ppm 137 ppm

[0064] FIG. 3 provides a schematic comparison between three methods: (1) a hydrometallurgical method of producing a cathode material in accordance with the present disclosure; (2) a pyrometallurgical process; and (3) another hydrometallurgical process. The method according to the present disclosure includes providing LiB waste (S200), performing mechanical separation (S202) to obtain black mass 10, leaching and removing impurities (S204), and performing a co-precipitation step (S206) to produce a cathode precursor 30, followed by cathode material production (S208) to produce the cathode material 32. As schematically illustrated in FIG. 3, the method according to the present disclosure does not lose Li to slag or generate toxic gas as occurs in the pyrometallurgical process. Moreover, as schematically illustrated in FIG. 3, the method according to the present disclosure bypasses (S210), that is, does not include, separation and purification steps (S300) to produce battery grade components 40. Such separation and purification steps (S300) are costly aspects of the other hydrometallurgical process illustrated in FIG. 3, which may be avoided by performing the method according to the present disclosure.

[0065] As used herein, unless otherwise specified, all numbers such as those expressing values, ranges, amounts or percentages may be read as if prefaced by the word “about,” even if the term does not expressly appear. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include any and all sub-ranges between and including the recited minimum value of 1 and the recited maximum value of 10, that is, all subranges beginning with a minimum value equal to or greater than 1 and ending with a maximum value equal to or less than 10, and all subranges in between, e.g., 1 to 6.3, or 5.5 to 10, or 2.7 to 6.1. Plural encompasses singular and vice versa. When ranges are given, any endpoints of those ranges and/or numbers within those ranges can be combined within the scope of the present disclosure. “Including,” “such as,” “for example,” and like terms means “including/such as/for example but not limited to.”

[0066] The methods recited in the claims which follow should not be limited by the order in which steps are listed.