Simultaneous recycling of nickel metal hydride, lithium ion and primary lithium batteries: Accomplishment of European Guidelines by optimizing mechanical pre-treatment and solvent extraction operations

In this paper the recycling of nickel metal hydride (NiMH), lithium ion (Li-ion) and primary lithium batteries was examined. Three mechanical routes of treatment were developed for each type recovering mainly three fractions: ferrous metals, non-ferrous metals and electrodic powders. The above mentioned types of spent batteries were also treated together by a unique mechanical route, obtaining in this way a powder enriched in cobalt, nickel and manganese which can be further extractable by chemical leaching. Experimental tests of solvent extraction were performed on synthetic leach liquors simulating a feed mixture of spent devices with weight composition 40% NiMH, 40% primary lithium, and 20% Li-ion (as determined by manual sorting of 3 tons of end of life batteries collected in Northern Italy). Under these conditions nickel and cobalt can be easily separated by using Cyanex 272 (stoichiometric ratio Cyanex/Co = 4, pH 5–6), but in presence of manganese Cyanex 272 loses its selectivity towards cobalt. Thus manganese must be preliminarily removed by using D2EHPA (stoichiometric ratio D2EHPA/Mn = 2, pH 4). Mechanical treatments and hydrometallurgical section to recover metals from electrodic powder are unavoidable operations in order to recover at least 50% of batteries as weight according to European Guideline 2006/66/EC.

► Mass balances of pilot scale mechanical pre-treatment schemes for battery recycling.
► Pre-treatment of NiMH, Li-ion and primary Li batteries and their mixtures.
► Solvent extraction optimization for the separation of Mn, Co and Ni in leach liquors.