Publication date: 15th December 2025
Direct recycling of active materials from Li-ion batteries preserves the structure of the materials, rather than separating them into their constituent elements. This offers an energy and resource efficient recycling route for relevant materials, when compared to process such as hydrometallurgy and pyrometallurgy. Direct recycling has stringent requirements, including high material purity, thus most direct recycling is conducted on single-component feeds of cathodes from production scrap or manually disassembled cells. Manual disassembly is expensive, hazardous, and challenging to scale.
This presentation highlights the integration of a novel and scalable shredding process applied to NMC532 pouch cells, followed by separator and casing removal through electrostatic separation, and subsequent anode/ cathode sorting via high intensity magnetic separation. Thermal debinding was used to produce cathodic black mass with <1 wt% impurity, separate from the anodic black mass isolated earlier in the process. The cathodic active material was found to be Li-deficient, and relithiated using commercial or recycled Li2CO3 to Li1Ni0.5Mn0.3Co0.2O2. The morphology of the cathodic active material was preserved throughout the process, and manufactured into electrodes, achieving discharge capacities up to 142mAh g-1 after formation.
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