PVC-Mediated Chlorination Roasting Enables Green and Selective Lithium Recovery From Mixed Spent LiMn₂O_4-LiCoO₂...

Area of Science:

• Materials Science
• Chemical Engineering
• Environmental Science

Background:

• Spent lithium-ion batteries pose a growing environmental challenge.
• Current recycling methods often lack efficiency and economic viability for lithium recovery.

Purpose of the Study:

• To develop a novel, green, and economic process for selective lithium recovery from mixed spent LiMn2O4-LiCoO2 batteries.
• To investigate the underlying thermodynamic and kinetic mechanisms of the proposed recycling process.

Main Methods:

• A PVC-mediated chlorination roasting process was developed.
• Thermodynamic analysis, thermal behavior analysis, phase evolution analysis, and density functional theory (DFT) calculations were employed.
• Optimized roasting conditions (600°C, 1:1.2 ratio, 120 min) were determined.

Main Results:

• Achieved 97.28% lithium recovery efficiency and 98.86% lithium selectivity.
• LiCl formation was thermodynamically favorable, with preferential chlorination of lithium.
• Produced battery-grade Li2CO3 (99.65% purity) and captured over 80% of released chlorine.
• Economic assessment indicated a net profit of $3,418.5 per metric ton.

Conclusions:

• The PVC-mediated chlorination roasting process offers a sustainable and economically viable strategy for selective lithium extraction from spent batteries.
• This approach synergistically integrates battery recycling with plastic waste management within a circular economy framework.
• The process demonstrates high efficiency, selectivity, and environmental benefits, including chlorine capture.