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Lithium-ion battery recycling through an integrated electro-membrane crystallization technology.

Yan Zhao1,2, Yangbo Qiu3, Lei Xia4

  • 1Department of Civil Engineering, The University of Hong Kong, Pokfulam, Hong Kong. yanzhaox@hku.hk.

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|December 20, 2025
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This study introduces electro-membrane crystallization-assisted general recycling (e-MCGR), a scalable technology for efficiently recovering valuable metals from spent lithium-ion batteries (LIBs). The e-MCGR process significantly enhances LIB recycling sustainability and economic viability.

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Area of Science:

  • Materials Science
  • Chemical Engineering
  • Environmental Science

Background:

  • Lithium-ion battery (LIB) recycling is critical due to the accumulation of spent batteries and the need for resource recovery.
  • Current methods face challenges in selectively and efficiently recovering valuable metal ions like Li+, Mn2+, Ni2+, and Co2+ from complex leaching solutions.

Purpose of the Study:

  • To develop and evaluate a scalable electro-membrane crystallization-assisted general recycling (e-MCGR) technology.
  • To achieve selective and efficient recovery of key metal ions from LIB leaching solutions.

Main Methods:

  • Integration of electrochemical and electro-membrane technologies into four configurations: selective membrane dual-stage distillation, bipolar membrane in-situ crystallization, membrane metal-complexing ex-situ crystallization, and membrane metal-extracting temporal crystallization.
  • Systematic analysis of electro-membrane kinetics, crystallization performance, energy consumption, economic viability, and environmental benefits.

Main Results:

  • Optimized e-MCGR achieved high recovery rates: 95.5% for Li+, 99.5% for Mn2+, 83.1% for Ni2+, and 87.3% for Co2+.
  • High product purities were obtained: 99.9% for Li2CO3, 99.9% for Mn3O4, 99.5% for Ni(OH)2, and 92.5% for Co(OH)2.

Conclusions:

  • The e-MCGR technology offers a scalable and efficient solution for LIB recycling.
  • This approach aligns technological performance with energy, environmental, and economic sustainability, potentially transforming LIB recycling practices.