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Recycling of Spent Lithium Nickel-Cobalt Batteries

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Recycling of Spent Lithium Nickel-Cobalt Batteries RECYCLING OF SPENT LITHIUM NICKEL-COBALT BATTERIES THROUGH LEACHING OF NICKEL AND COBALT FROM CATHODE MATERIAL By Kristian Monteiro An honours research thesis submitted to Murdoch University In fulfilment of the requirements for the Degree of Bachelor (Hnrs) in Chemical and Metallurgical Engineering Department of Chemical and Metallurgical Engineering Murdoch University 2018 Supervisor: Dr Aleks Nikoloski ii | P a g e Author’s Declaration I declare that the following work presented is my own, unless otherwise specified, and the research carried out was under the supervision of Dr Aleks Nikoloski and Dr. Asem Mousa during the years of 2017-2018. This thesis is submitted as part of the requirements for the Bachelor (Hnrs) of Chemical and Metallurgical Engineering degree to the school of Engineering and Information Technology, Murdoch University, Western Australia. This thesis has not previously been submitted for a degree at any tertiary education institution. Kristian Monteiro 7th June, 2018 iii | P a g e iv | P a g e Abstract This research paper investigates a hydrometallurgical approach that includes the leaching of spent lithium-ion battery cathode material. The targeted elements to be recovered are cobalt and nickel which are identified to be the cost drivers in the lithium-ion battery to date. The observation of parameters surrounding the leaches give a brief but excellent understanding into the recovery mechanisms and extraction stages of nickel and cobalt in a sulphuric acid and hydrogen peroxide medium. The recycling of lithium ion batteries is trending to become one of the major processes in the recycling industry heading forward. As more appliances and technologies look to lithium ion batteries for an energy storage system, it is crucial that the supply is not hindered with the increase in demand for the battery. The eventual commercialization of a hydrometallurgical process will most likely be based around the leaching of the spent lithium ion batteries and the recovery of valuable metals. Although further test work is necessary to achieve credible and reliable results, this thesis demonstrates the effect of the change in parameters within the test work which leads to the recovery of nickel and cobalt from waste lithium ion batteries. 113.2 % cobalt and 98.6 % nickel were recovered with the leaching of cathode material while 109.6 % cobalt and 100.5 % nickel were extracted with the leaching of separator material. The increased recovery at a lower cost will generally lead to a commercialised process that will in the future be used to process all spent lithium- ion batteries. This thesis looks at the broader scope of the energy storage system market, identifies the cost driver and looks to decrease that cost driver for a viable and cost effective process. v | P a g e vi | P a g e Acknowledgements As I look back on the last four and a half years of this degree, it is staggering to see how much has changed. It is a reminder of the good people who have made all of this possible. I firstly would like to thank Dr Aleks Nikoloski for his ongoing support in not only this thesis but also throughout the degree. Having a supervisor with so much knowledge and willingness to guide allowed the process of this last step to be relatively smooth. The enthusiasm expressed in each meeting will not be forgotten, thank you. I would also like to thank Dr Asem Mousa for his willingness to give up time and valuable knowledge that helped with the research. Dr Mousa’s extensive knowledge into battery systems helped me with the initial stages right through to the test work of this thesis. I would like to thank the tutors and lecturers I have had the privilege of studying under throughout my time in this degree. Notably associate professor Gamini Senanyake for his teachings throughout the years. To my friends who I have met pre-university and friends I have made in university, thank you for supporting and encouraging throughout these years. Bryce, Mike, Shannon, Lia and Daniel, thank you for the laughs and hangouts over the last couple of years. My girlfriend Raquel, thank you for the unwavering support over the last 4 years. Thank you for your patience and guidance, without you this would not have been possible. Thank you for your sacrifice at times to put your life on hold for me. Last but not least to my family. Mum, Dad, Josh, Luke and George, it is not possible to thank you enough for the support, wisdom and encouragement through some of the hardest times in my life. I hope that in some way, shape or form I have made you proud. I could not have asked for better people to be by my side through my university life. For this, thank you God. vii | P a g e viii | P a g e Contents Chapter 1 – Introduction ................................................................................................... 1 1.1 Overview ....................................................................................................................................... 1 1.2 Motivation for Study ..................................................................................................................... 2 1.3 Leaching Using Hydrogen Peroxide and Sulfuric Acid................................................................... 3 1.4 Scope and Objectives .................................................................................................................... 4 Chapter 2 – Literature Review ........................................................................................... 5 2.1 Introduction .................................................................................................................................. 5 2.2 Background ................................................................................................................................... 5 2.2.1 Lithium – Ion Batteries ....................................................................................................... 6 2.2.2 Zinc - Bromine Batteries ..................................................................................................... 7 2.2.3 Nickel Metal – Hydride ....................................................................................................... 8 2.2.4 Vanadium Redox Flow ....................................................................................................... 9 2.2.5 Lead – Acid ....................................................................................................................... 10 2.3 Battery Operation and Chemistry ............................................................................................... 11 2.3.1 Lithium – Ion .................................................................................................................... 11 2.3.2 Zinc – Bromine ................................................................................................................. 12 2.3.3 Vanadium Redox Flow ..................................................................................................... 13 2.3.4 Nickel Metal – Hydride ..................................................................................................... 14 2.3.5 Lead – Acid ....................................................................................................................... 15 2.4 Leading Developers ..................................................................................................................... 17 2.5 Battery Materials & Chemicals ................................................................................................... 19 2.5.1 Chemical Compositions and Concentrations ................................................................... 20 2.5.2 Varied Materials ............................................................................................................... 20 2.6 Processing ................................................................................................................................... 23 2.7 Major Ore Deposits and Mineralogy ....................................................................................... 24 2.7.1 Vanadium ......................................................................................................................... 24 2.7.2 Nickel ................................................................................................................................ 25 2.7.3 Lead .................................................................................................................................. 26 2.7.4 Lithium ............................................................................................................................. 26 2.7.5 Zinc ................................................................................................................................... 27 2.7.6 Cobalt ............................................................................................................................... 27 2.7.7 Reserve and Production Summary ................................................................................... 27 ix | P a g e 2.8 Processing Options .................................................................................................................. 29 2.8.1 Nickel ................................................................................................................................ 29 2.8.2 Lead .................................................................................................................................
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