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Material Recovery: Key Approaches
Physical Pre-treatment
Hydrometallurgy
Discharging, shredding, and separation
Acid/alkaline leaching of black mass selective separation via:
Solvent Extraction
Precipitation
Ion exchange
Recovery of:
Cu & Al foils
Black mass (Li-Ni-Co-Mn rich fraction)
Graphite
Recovers Li, Ni, Co, Mn with high purity Most widely adopted industrial route
Pyrometallurgy High-temperature smelting (>1200 °C) Recovers: Ni, Co, Cu (alloy phase) Limitations: Lithium mostly lost to slag High energy consumption Limited compositional control
Source: [1] Asad ali et al, j.jenvman. 2025, 391, 126512; [2] Xiaotu Ma et al, Nat. Rev. Clean Technol. 2025, 1, 75–94; [3] BK Biswal et al, Chem. Soc. Rev., 2024, 53, 5552-5592.
Direct Regeneration Preserves cathode crystal structure Re-lithiation and surface reconstruction Benefits:
Lower energy input
Higher value retention Challenges:
Feedstock variability
Process scalability
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