How lithium-ion batteries are recycled

Lithium-ion battery recycling involves collecting, discharging, and dismantling used batteries. Valuable metals like Li, Co, Ni, and Mn are extracted from the resulting black mass. Hydrometallurgical or pyrometallurgical methods recover these metals. The recovered metals are then reused in new batteries.

Challenges in recycling include the variety of battery chemistries, such as NMC and LMFP, with varying compositions. Accurate characterization of black mass is essential for efficient recycling.

Our X-ray and neutron-based solutions can analyze chemical composition and crystalline phases. Our XRF solutions evaluate hydrometallurgical leaching efficiency and impurity analysis. Additionally, our particle size analyzers measure particle size throughout the recycling process.

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Chemical analysis of recycled li-ion batteries

Elemental analysis of black mass can be done online with our CNA cross belt analyzer or offline using XRF systems.

Our CNA Pentos cross belt analyzer provides real-time elemental analysis of bulk black mass. It uses PFTNA technology to measure key elements like Ni, Co, Mn, Fe, P, etc. This non-destructive analysis is ideal for heterogeneous materials and process control.

X-ray fluorescence (XRF)

An alternative to inductively coupled plasma (ICP) spectroscopy

XRF is a simpler alternative to ICP for analyzing chemical composition in battery materials. It can measure elements and impurities from ppm to 100%. Our Epsilon 4 EDXRF and Zetium WDXRF spectrometers are used by many battery companies. Our new Revontium EDXRF analyzes black mass with high accuracy.

The Importance of Calibration Standards

Accuracy of XRF analysis depends on the quality of calibration standards. Malvern Panalytical has developed its in-house certified calibration standards, which together with the Eagon 2 or FORJ sample fusion systems can provide a perfect recipe for accurate quantitative elemental analysis.

Figure 1 (left): A typical calibration line of Ni using our NCM reference standards measured on our Epsilon 4 XRF spectrometer.

Our solutions for the chemical analysis of recycled li-ion batteries

Compact brilliance, powerful analysis, endless possibilities

Revontium

Fast and accurate at-line elemental analysis

Epsilon 4

Smart Zetium for reliable results and robust operation

Zetium

The world’s fastest, safest and most accurate fusion instrument for sample...

FORJ

Fully automatic fusion machine for XRF analysis

Claisse Eagon 2

Claisse [Forj] does not only provide high quality and reliable instruments, it also takes the operator’s safety and the customers’ entire satisfaction into consideration.

Maria Petrov — BASF

Analysis of leached solutions

The elemental composition analysis of the leached solutions in hydrothermal extraction can provide valuable information about metal extraction efficiency. This can be analyzed in line with our Xflow range of XRF analyzers. On-line liquid analysis with the Epsilon Xflow enables fast and accurate control of your process parameter. Epsilon Xflow provides real-time data insights, enabling you to manage your production processes more efficiently and reduce your operational costs.

Crystalline phase analysis of black mass

The battery recycling pre-treatment process may also be affected by the crystalline phase of the battery materials. And, when it comes to crystalline phase analysis, X-ray diffraction is the technique of choice. Our Aeris X-ray diffractometer – an easy-to-use instrument with superb data quality – can be used to accurately analyze crystalline phase composition in black mass and recycled battery materials.

Figure 2 (left): Typical XRD analysis of black mass crystalline phases measured on our Aeris diffractometer.

Our solutions for analysing leach solutions and the crysaline phase

Direct insight into your liquid process parameters

Epsilon Xflow

The future is compact

Aeris

Particle size and shape

Particle size and shape play an important role across the entire value chain of battery recycling from black mass to finished output materials. Black mass needs to be ground to a certain particle size for efficient leaching of metals during hydrothermal extraction. Many recycling companies produce battery precursor or electrode materials as their end-product, where particle size and shape are used as critical quality parameters.

Our solutions for measuring particle size and shape in battery recycling

The smartest way to measure particle size

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A window into deeper materials analysis

Hydro Insight

View our related resources for battery recycling

Application note

n recent years, lithium-ion batteries have revolutionized the energy storage landscape by powering portable electronics, electric vehicles, and renewable energy storage systems. Among the various types of lithium-ion batteries, lithium nickel manganese cobalt oxide (Li-NMC) batteries have emerged as a prominent choice due to their high energy density, improved stability, and established industrial-scale production. The chemical composition of Li-NMC cathode materials plays a critical role in determining their performance, making accurate elemental analysis of these materials essential for battery development and production.

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