Qingxin
Zheng
*a,
Kensuke
Shibazaki
b,
Tetsufumi
Ogawa
b,
Atsushi
Kishita
a,
Yuya
Hiraga
a,
Yuta
Nakayasu
c and
Masaru
Watanabe
*ad
aResearch Center of Supercritical Fluid Technology, Department of Chemical Engineering, Graduate School of Engineering, Tohoku University, 6-6-11 Aoba, Aramaki, Aoba-ku, Sendai, 980-8579 Japan. E-mail: qingxin.zheng.a2@tohoku.ac.jp; masaru.watanabe.e2@tohoku.ac.jp
bFaculty of Environmental Studies, Tohoku University, 6-6-11 Aoba, Aramaki, Aoba-ku, Sendai, 980-8579 Japan
cFrontier Research Institute for Interdisciplinary Sciences, Tohoku University, 6-6-11-406 Aoba, Aza, Aramaki, Aoba-ku, Sendai 980-8578, Japan
dEnvironment Conservation Center, Department of Chemical Engineering, Graduate School of Engineering, Tohoku University, 6-6-11 Aoba, Aramaki, Aoba-ku, Sendai, 980-8579 Japan
First published on 3rd August 2020
The first run of continuous hydrothermal leaching of lithium-ion battery cathode materials, LiCoO2, was performed using citric acid as the leachant at 200 °C. The flow system was specially designed and customized. Prior to the hydrothermal leaching experiments, a three-layer model was used to predict the flow state in this flow system, and a cold flow test using two kinds of flow lines was performed to determine the conditions in the preliminary experiments. Finally, the pulp density of the slurry and the flow rate were set to 10 g L−1 and 30 ml min−1, respectively, for the continuous hydrothermal leaching experiments. At 60 min after the start of slurry feeding, the leaching efficiency of Li and Co reached 81.3% and 92.7%, respectively, and can continue to increase with the extension of time. The successful run indicated that the process of hydrothermal leaching is feasible and promising to be applied in practice. Meanwhile, a problem of acid corrosion caused by the use of citric acid during this process was revealed and is expected to be resolved using inner coating materials with high acid corrosion resistance or organic acids with low or no acid corrosion as the leachant.
LIB cathode materials are usually composed of lithium-containing oxides of transition metals, such as LiCoO2, LiNiO2, LiMn2O4, LiFePO4, LiMnPO4, LiCoPO4, and their mixtures.4 The metal components in LIBs need a stable supply to meet the increasing consumption; however, some of them are mainly produced from a limited number of countries or geographically remote areas and thus have unstable supplies caused by geopolitical issues.6,7 For example, about 70% of Co is produced by Congo (59%), Australia (5%), and Russia (7%).8 The mining supply of metals, such as Li and Co, is predicted to reach their limits and will be exceeded by the demand soon. On the other hand, spent LIBs are regarded as a kind of hazardous solid waste, which would bring a tremendous burden on the environment and resource conservation.2 Therefore, efficient recovery of valuable metals (e.g., Li, Co, Ni, and Mn) from spent LIBs under mild conditions will be essential to conserve natural resources, reduce environmental problems, keep resource stability and security, and bring economic benefits.9 As the first type of commercialized cathode material, LiCoO2 has been widely employed in most commercial LIBs, and recently, the quantity of discarded LiCoO2 has increased regularly and continuously.10 Compared with other LIB materials, spent LiCoO2 is always regarded as a worthy target for recycling because it is rich in Li and Co.11
Hydrometallurgy is one of the conventional methods for recovering metal components from spent LIBs in the lab and industry, composed of acid leaching in the first step and separation in the second step.12,13 In the leaching stage, spent LIB cathode materials, such as LiCoO2, LiNiO2, and LiMn2O4, are converted to an aqueous solution of mixed metal ions. A traditional and well-known process is leaching metal ions with a mineral or an inorganic acid (e.g., sulfuric acid or nitrate acid) in non-pressurized hot water.14 Meanwhile, chemical reductants (e.g., H2O2, NaHSO3, or Na2S2O3)15 are added to improve the leaching efficiency and lower the required concentration of acids. Due to its drawbacks in terms of high-concentration inorganic acids, consumption of reductants, batch-style apparatus, long time, and strong acid corrosion, the traditional leaching process always brings severe environmental pollution and economic burden. Therefore, making this process a greener and more environmentally-friendly step-by-step one is attracting increasing attention.
As shown in Scheme 1, looking for alternatives to inorganic acids is the first stage in the green progress of the acid leaching process for LiCoO2. Compared to inorganic acids, organic acids are milder with lower acid corrosion and pollution. To date, there have been plenty of reports on the leaching of metal ions from spent LIB cathode materials using organic acids as the leachant, such as succinic acid,16 malic acid,17 aspartic acid,17 citric acid (H3Cit),18–20 acetic acid,21 lactic acid,22 tartaric acid,23 oxalic acid,24 glycine,25 and so on. These achievements have proved that organic acids could displace inorganic acids for the acid leaching process. However, reductants are still indispensable for reducing the transition metal ions from a high to a low state.18 For example, without reductants, the leaching efficiencies of Li and Co decreased significantly, despite the use of inorganic or organic acids.6,7,17,26
Scheme 1 The green progress of the acid leaching process for LiCoO2. The words marked in red color are the problems to be resolved. |
To date, two feasible paths have been reported to avoid the consumption of additional reductants. The one is leaching with ascorbic acid.27 During this process, ascorbic acid plays the roles of both a leachant and reductant. Another one was proposed in 2017, using pressurized hot water to leach Li and Co from LiCoO2 with H3Cit, and the process was also called ‘hydrothermal leaching’.26 Without using any reductant like H2O2, hydrothermal leaching with H3Cit (0.4 mol L−1) achieved a leaching efficiency of 94% for both Li and Co at 200 °C for 10 min.26 This good performance was attributed to H3Cit which supplies a proton, forms a soluble complex with Co, and shows reducibility even though H3Cit does not work as a reductant below 100 °C. Different from the traditional leaching process using non-pressurized hot water, the temperature of the hydrothermal leaching process is not limited by the boiling point of water at 100 °C. The use of high temperature greatly accelerates the reaction, shortens the reaction time, and decreases the required concentration of acid.28 With a lower concentration of acids, no consumption of reductants, and a higher reaction rate, hydrothermal leaching is more efficient and environmentally friendly than the traditional leaching method, although an organic acid is used in each of them.
One of the next targets in the green progress is developing the leaching apparatus from a batch to a continuous flow system, which can enhance the productivity, reduce the processing time, improve the quality, have lower reagent and power consumption, save the costs, facilitate the scale-up, and move forward to the industrial application.29,30 To our knowledge, continuous acid leaching of metal components from LIB cathode materials using a flow system has never been achieved in any conventional hydrometallurgy process, due to possible reasons such as the long reaction time and severe acid corrosion caused by the use of inorganic acids or high-concentration organic acids. Performed in pressurized hot water with low-concentration organic acids, the hydrothermal leaching method becomes one of the promising candidates to realize continuous leaching, but its development is still in the initial stage and the device is currently limited to the batch-style apparatus with a small scale. Therefore, at the current stage, a flow system, in which the hydrothermal leaching can be performed continuously, is urgently demanded.
In this study, we applied a specifically designed and customized flow system to perform the continuous hydrothermal leaching of LiCoO2 using H3Cit as the leachant for the first time. The preliminary conditions such as the pulp density of the slurry and flow rate were determined based on the results of a three-layer model and a cold flow test without heating. During the first run of continuous hydrothermal leaching experiments, the experimental conditions were given in detail, the flow system was modified, the results of leaching efficiency were obtained, and problems such as acid corrosion as well as feasible resolutions were considered.
Step 1 | Step 2 | Step 3 | Step 4 | Step 5 | Step 6 | |
---|---|---|---|---|---|---|
a The preheaters or heaters were heated step by step to the specific temperatures. | ||||||
Pre-heater 1 | 150 | 180 | 180 | 200 | 200 | 200 |
Pre-heater 2 | 150 | 180 | 180 | 200 | 200 | 200 |
Heater 1 | 100 | 125 | 150 | 180 | 200 | 200 |
Heater 2 | 100 | 125 | 150 | 180 | 200 | 200 |
Heater 3 | 70 | 100 | 125 | 150 | 180 | 195 |
Heater 4 | 40 | 80 | 100 | 120 | 150 | 190 |
After the temperature became unchanged, the supply of pure water was stopped, and the H3Cit aqueous solution was supplied into the system from tank A. After about 15 min, the water in the system was completely displaced by the H3Cit solution. After confirming that the pressure was maintained, there was no leakage, and the heating was stable, the supply of the H3Cit aqueous solution was stopped, and the supply of the slurry was started. During the experiment, the slurry in the feeding tank was stirred at a speed of 600–800 rpm using a 4-blade stirrer (AS ONE, SM-101) to suppress solid–liquid separation. Sampling was started after the slurry was fed for 15 min, and performed 10 times with an interval of 5 min.
Leaching efficiency is defined as the percentage of the mass of the metal ion in the recovered solution against the total mass of the metal ion in the starting material. The calculation equation (eqn (1)) is shown as follows.
(1) |
Fig. 2 shows the relationship between the pulp density and the flow rate of the LiCoO2 slurry calculated using the three-layer model. The density of LiCoO2 is 5000 kg m−3, and the average particle size is 12.4 μm based on the particle size distribution shown in Fig. S1.† The density (ρL) and viscosity (μL) of the H3Cit aqueous solution were assumed to be similar to those of water. The viscosity of the slurry (μs) was assumed to be similar to that of water. In Fig. 2, the area above the solid line represents the full suspension area (H layer), where the liquid flows without forming a deposit, and the bottom area is the moving bed area (MB layer) that is transported while forming a deposit. From Fig. 2, it was found that at a flow rate of 10 ml min−1, the slurry can be transferred without deposition when the pulp density was less than about 21 g L−1, while at a pulp density of 50 g L−1, the LiCoO2 particles can deposit in the tube, making a stable liquid transfer difficult to achieve. This gave a good explanation for the experimental results shown in Fig. 1.
Fig. 3 shows the effect of time on the pulp density of the recovered solution using flow line B. When the pulp density of the slurry was 1 g L−1, the recovered solution has a stable pulp density in each of the six samplings. When the slurry pulp density increased to 10 or 20 g L−1, the pulp density of the recovered solution was stable in the first five samplings, but then dropped in the 6th time. Particularly at a slurry pulp density of 20 g L−1, the pulp density of the recovered solution in the 6th sampling decreased a lot to almost a half. From Fig. 2, under the conditions of 10 or 20 g L−1 (pulp density of the feeding slurry) and 30 ml min−1 (flow rate), it is in the full suspension range and accumulation should not occur. The conflict again illustrates the difference between the theoretical model results and the actual experimental results. A possible reason for the decrease in the 6th time is that the particles accumulate in the slurry pump as time elapses from the start of the slurry feeding, and then the feeding performance is impaired. The LiCoO2 particles might deposit in the slurry pump and cause blockage, thereby lowering the transfer rate. That is, it can be expected that a long-term operation will be difficult for this flow system when the pulp density of the slurry is high.
Fig. 3 Effect of time on the pulp density of the recovered solution using flow line B (LiCoO2, 30 ml min−1). |
Based on the above results, the pulp density of the slurry and the flow rate were set to 10 g L−1 and 30 ml min−1, respectively, in the next continuous hydrothermal acid leaching experiments.
Fig. 4 shows the leaching efficiency of Li and Co at different times during the continuous hydrothermal leaching of LiCoO2 with H3Cit (0.4 mol L−1). At 15 min after the start of slurry feeding, which was the first sampling, the leaching efficiencies of Li and Co were 64% and 74%, respectively. Then, the leaching efficiency of the metals increased gradually with the extension of time, which can be attributed to the replacement of the H3Cit aqueous solution in the system with the slurry being insufficient immediately after the switching. At 60 min, which was the 10th sampling, the leaching efficiency of Li and Co achieved 81.3% and 92.7%, respectively, approaching the data obtained using a batch-style apparatus at 15 min.26 Therefore, the recovered solution or leachate with a high leaching efficiency can be collected continuously after 60 min of slurry feeding, even if the leaching efficiencies of Li and Co are expected to increase even after 60 min.
Fig. 4 Effect of time on the leaching efficiency of Li and Co during the continuous hydrothermal leaching of LiCoO2 with H3Cit. |
This is the first time to achieve continuous leaching of LIB cathode materials by a hydrothermal method. Even though the current conditions may be far from the optimum, the results are sufficient to prove the feasibility of the continuous hydrothermal leaching process and the applicability of this flow system.
Table 2 shows the concentration of each metal ion in the recovered solutions at different times during hydrothermal leaching of LiCoO2 with H3Cit. Except for Li and Co, Ni, Fe, Cr, and a tiny amount of Mn were detected. As a pure LiCoO2 compound was used in this study, the source of the other metal ions might be the steel materials used in the flow system. After comparing with the elemental composition of the stainless steel used in the flow system, SUS306 and SUS3016, as listed in Table 3, it can be inferred that the other metal ions must originate from the steel tubes used in the flow system. Additionally, the variation trend of the concentration with the extension of time was different for different metal ions. With the extension of time, the concentration of Li, Co, and Ni increased, while that of Mn, Fe, and Cr decreased first and then tended to be unchanged. This is probably because at the beginning of the reaction, H3Cit corrodes the pipe and then the wall of the tube is ‘protected’ by the accumulation of LiCoO2 as the reaction proceeds.
Time [min] | Li [ppm] | Co [ppm] | Ni [ppm] | Mn [ppm] | Fe [ppm] | Cr [ppm] |
---|---|---|---|---|---|---|
a H3Cit: 0.4 mol L−1; flow rate: 30 ml min−1. | ||||||
15 | 472.9 | 4553.2 | 103.7 | 7.9 | 301.0 | 85.5 |
20 | 528.1 | 5138.2 | 103.9 | 6.4 | 275.7 | 79.3 |
25 | 555.8 | 5358.5 | 109.0 | 6.1 | 258.6 | 77.1 |
30 | 573.0 | 5551.5 | 115.9 | 5.9 | 246.1 | 74.8 |
35 | 591.3 | 5682.3 | 120.2 | 5.8 | 240.8 | 73.6 |
40 | 596.7 | 5800.4 | 126.6 | 5.6 | 235.9 | 74.6 |
45 | 611.7 | 5899.4 | 131.4 | 5.4 | 230.8 | 75.1 |
50 | 638.9 | 6071.5 | 139.0 | 5.8 | 236.9 | 77.5 |
55 | 650.5 | 6255.9 | 148.0 | 5.8 | 235.8 | 78.0 |
60 | 666.0 | 6412.9 | 151.8 | 5.6 | 234.2 | 78.4 |
Ni [wt%] | Mn [wt%] | Fe [wt%] | Cr [wt%] | |
---|---|---|---|---|
a The steel types include SUS304 and SUS316. | ||||
SUS304 | 8–11 | <2 | 67–69 | 18–20 |
SUS316 | 10–14 | <2 | 64–66 | 16–18 |
The acid corrosion revealed here is an obvious problem in the further application, but its severity is much lower than that caused by the use of inorganic acids or high-concentration organic acids in the conventional leaching method. It is known that the acids must be used in all current leaching processes. Even though the corrosion caused by the acids cannot be eliminated completely, its damage is being reduced gradually in the green progress. For example, there are several feasible ways to avoid or suppress acid corrosion. One is to apply Teflon or coating materials with high acid corrosion resistance to the inner wall of the tubes. Another one is to choose organic acids with low or no acid corrosion as the leachant. In addition, continuous manufacturing is an unavoidable step before the practical application. Therefore, this research is believed to be beneficial and significant to the sustainable development of continuous leaching of LIB cathode materials in the future.
Footnote |
† Electronic supplementary information (ESI) available: Information of the linear fitting lines for the plots used in the kinetic study. See DOI: 10.1039/d0re00286k |
This journal is © The Royal Society of Chemistry 2020 |