Valorization of Graphite from Spent Li-ion Battery Recycling Waste
Kerli Liivand a, Reio Praats a, Mari Lundström b, Benjamin P. Wilson b, Ivar Kruusenberg a
a National Institute of Chemical Physics and Biophysics, Akadeemia tee, 23, Tallinn, Estonia
b Department of Chemical and Metallurgical Engineering, School of Chemical Engineering, Aalto University
Materials for Sustainable Development Conference (MATSUS)
Proceedings of MATSUS Spring 2025 Conference (MATSUSSpring25)
Sustainable energy materials and circularity - #SusMat
Sevilla, Spain, 2025 March 3rd - 7th
Organizers: Tim-Patrick Fellinger and Cristina Pozo-Gonzalo
Invited Speaker, Kerli Liivand, presentation 391
DOI: https://doi.org/10.29363/nanoge.matsusspring.2025.391
Publication date: 16th December 2024

Li-ion battery (LIB) technology is a cornerstone of the transition to a carbon-neutral economy, powering advancements in renewable energy storage and electric mobility. While LIBs have been transformative, achieving full environmental and economic sustainability requires addressing challenges across the entire value chain, including the recycling of spent Li-ion batteries (SLIBs). Current industrial recycling processes primarily focus on recovering valuable cathode metals from the black mass. However, graphite, a critical raw material present in significant quantities in SLIBs, is largely discarded, despite its designation as a critical material by the EU. To fully capitalize on the circular economy potential of LIBs, innovative strategies for the recovery and upcycling of spent graphite are urgently needed.

Recycling graphite from black mass leach residue faces significant challenges due to impurities, structural defects, and contaminants that make traditional recycling methods economically unfeasible. This presentation outlines a novel approach utilizing hydrometallurgically-leached black mass residue as a raw material for producing bifunctional oxygen electrocatalysts. By exploiting the residual metal content and defects in the waste graphite we are able to turn a disposal challenge into an opportunity for creating high-value materials. Our research [1, 2] demonstrates the potential of SLIB recycling residue as a sustainable resource for high-performance M-N-C catalyst materials. These novel catalysts, tested in Zn-air batteries, show high power density and long cycling stability, highlighting their applicability in next-generation energy devices, offering a pathway toward mitigating climate change while advancing the circular economy for battery technologies.

This research has been supported by the Estonian Research Council (PSG926), as well as the Business Finland BatCircle2.0 (Grant Number 44886/31/2020) project. In addition, this work was funded by the Ministry of Education and Research through the Centre of Excellence in Circular Economy for Strategic Mineral and Carbon Resources (01.01.2024–31.12.2030, TK228). And the Academy of Finland’s RawMatTERS Finland Infrastructure (RAMI) based at Aalto University and the OtaNano – Nanomicroscopy Center (Aalto-NMC) were utilized as part of this research.

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