Sustainable bioleaching of lithium-ion batteries for critical metal recovery: Process optimization through design of experiments and thermodynamic modeling

Alipanah, Majid; Jin, Hongyue; Zhou, Qiang; Barboza, Caitlin Ann; Gazzo, David; Thompson, Vicki S.; Fujita, Yoshiko; Liu, Jiangping; Anderko, Andrzej; Reed, David W.

doi:10.1016/j.resconrec.2023.107293

Title: Sustainable bioleaching of lithium-ion batteries for critical metal recovery: Process optimization through design of experiments and thermodynamic modeling

Journal Article · 03 November 2023 · Resources, Conservation and Recycling

DOI: https://doi.org/10.1016/j.resconrec.2023.107293 · OSTI ID:2274767

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Univ. of Arizona, Tucson, AZ (United States)
Idaho National Laboratory (INL), Idaho Falls, ID (United States)
Idaho National Laboratory (INL), Idaho Falls, ID (United States); University of Notre Dame, IN (United States)
OLI Systems, Inc., Parsippany, NJ (United States)

Recycling spent lithium-ion batteries (LIBs) could alleviate supply risks for critical metals and be less harmful to the environment compared to new production of metals from mining. Developing a cost-effective LIB bioleaching process could be a promising alternative to traditional energy-intensive recycling technologies. Here, this study aimed to optimize bioleaching conditions for maximum economic competitiveness through design of experiments using iterative response surface methodology (RSM), assisted by thermodynamic modeling. The optimal condition was identified as 2.5% pulp density in 75 mM gluconic acid biolixiviant at 55°C for 30 h which could recover 57%–84% of nickel, 71%–86% of cobalt, and 100% of lithium and manganese, yielding a 17%–26% net profit margin. The recommended pulp density and acid concentrations, together with the observed metal solubilization, were supported by thermodynamic modeling predictions. Our study demonstrated that combining RSM with thermodynamic simulations could be a powerful tool for optimizing bioleaching conditions.

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Research Organization:: Idaho National Laboratory (INL), Idaho Falls, ID (United States); Ames Laboratory (AMES), Ames, IA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC07-05ID14517; SC-21-556

OSTI ID:: 2274767

Alternate ID(s):: OSTI ID: 2369125

Report Number(s):: INL/JOU-22-70202-Revision-0; TRN: US2408091

Journal Information:: Resources, Conservation and Recycling, Vol. 199; ISSN 0921-3449

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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