Worth from Waste: Utilizing a Graphite-Rich Fraction from Spent Lithium-Ion Batteries as Alternative Reductant in Nickel Slag Cleaning

One possible way of recovering metals from spent lithium-ion batteries is to integrate the recycling with already existing metallurgical processes. This study continues our effort on integrating froth flotation and nickel-slag cleaning process for metal recovery from spent batteries (SBs), using anodic graphite as the main reductant. The SBs used in this study was a froth fraction from flotation of industrially prepared black mass. The effect of different ratios of Ni-slag to SBs on the time-dependent phase formation and metal behavior was investigated. The possible influence of graphite and sulfur contents in the system on the metal alloy/matte formation was described. The trace element (Co, Cu, Ni, and Mn) concentrations in the slag were analyzed using the laser ablation-inductively coupled plasma-mass spectrometry (LA-ICP-MS) technique. The distribution coefficients of cobalt and nickel between the metallic or sulfidic phase (metal alloy/matte) and the coexisting slag increased with the increasing amount of SBs in the starting mixture. However, with the increasing concentrations of graphite in the starting mixture (from 0.99 wt.% to 3.97 wt.%), the Fe concentration in both metal alloy and matte also increased (from 29 wt.% to 68 wt.% and from 7 wt.% to 49 wt.%, respectively), which may be challenging if further hydrometallurgical treatment is expected. Therefore, the composition of metal alloy/matte must be adjusted depending on the further steps for metal recovery.

Automated summary

Integrating froth flotation and nickel-slag cleaning process for metal recovery from spent batteries was studied using anodic graphite as the main reductant. The composition of metal alloy/matte needs to be adjusted depending on further steps for metal recovery, as increasing concentrations of graphite can affect the Fe concentration in both metal alloy and matte. The distribution coefficients of cobalt and nickel between the metallic or sulfidic phase and the coexisting slag increased with the increasing amount of spent batteries in the starting mixture.