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Microwave-enhanced carbothermal reduction for efficient recovery of valuable metals from spent lithium-ion batteries.

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Title: Microwave-enhanced carbothermal reduction for efficient recovery of valuable metals from spent lithium-ion batteries.
Authors: Zhang, Gui-Rong1 (AUTHOR) 202411060906@std.uestc.edu.cn, Li, Da-Shuai2 (AUTHOR) dashuai_li@csj.uestc.edu.cn, Huang, Xing-Yu1 (AUTHOR) 202511060904@std.uestc.edu.cn, Liu, Yuan-Long3 (AUTHOR) longlaw@sina.com, Cheng, Yan-Qing4 (AUTHOR) chengyq@tianneng.com, Tong, Ling1 (AUTHOR) tongling@uestc.edu.cn
Source: Waste Management. Jan2026, Vol. 211, pN.PAG-N.PAG. 1p.
Subjects: Lithium-ion batteries, Metal recycling, Metallurgical analysis, Scalability, Leaching, Waste recycling, Microwave devices, Energy consumption
Abstract: [Display omitted] • Efficient lithium extraction achieved through water leaching. • Near-complete recovery of Li, Ni, Co, and Mn. • Exhibits higher energy efficiency than conventional heating processes. • Demonstrates the scalability potential of microwave-assisted carbothermal reduction. In conventional recycling processes for spent lithium-ion batteries (LIBs), the black mass (BM) of spent LIBs is typically subjected to high-temperature treatment, followed by leaching of valuable metals using strong acids or alkalis. However, these processes are energy-intensive, environmentally detrimental, and costly. Herein, we proposed a microwave-enhanced carbothermal reduction (MECTR) method characterized by a rapid heating rate and high heating efficiency. Under microwave irradiation at approximately 20 W, the temperature of the BM was elevated to 545 °C, and LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM811) was completely decomposed within 10 min. Subsequently, lithium was selectively extracted via simple water leaching at room temperature, achieving a leaching efficiency of 96.07 %. Nickel, cobalt, and manganese were effectively leached using a 0.5 M sulfuric acid solution at 60 °C, with leaching efficiencies of 98.01 %, 98.53 %, and 99.50 %, respectively. In addition, the particle morphology and elemental distribution of the BM before and after microwave heating and water leaching were investigated using SEM-EDS, and the formation and leaching behavior of lithium carbonate were analyzed. This strategy, with significant advantages in terms of recovery efficiency, processing time, and energy consumption, provides a promising and sustainable alternative for the recycling of spent LIBs. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
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Abstract:[Display omitted] • Efficient lithium extraction achieved through water leaching. • Near-complete recovery of Li, Ni, Co, and Mn. • Exhibits higher energy efficiency than conventional heating processes. • Demonstrates the scalability potential of microwave-assisted carbothermal reduction. In conventional recycling processes for spent lithium-ion batteries (LIBs), the black mass (BM) of spent LIBs is typically subjected to high-temperature treatment, followed by leaching of valuable metals using strong acids or alkalis. However, these processes are energy-intensive, environmentally detrimental, and costly. Herein, we proposed a microwave-enhanced carbothermal reduction (MECTR) method characterized by a rapid heating rate and high heating efficiency. Under microwave irradiation at approximately 20 W, the temperature of the BM was elevated to 545 °C, and LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM811) was completely decomposed within 10 min. Subsequently, lithium was selectively extracted via simple water leaching at room temperature, achieving a leaching efficiency of 96.07 %. Nickel, cobalt, and manganese were effectively leached using a 0.5 M sulfuric acid solution at 60 °C, with leaching efficiencies of 98.01 %, 98.53 %, and 99.50 %, respectively. In addition, the particle morphology and elemental distribution of the BM before and after microwave heating and water leaching were investigated using SEM-EDS, and the formation and leaching behavior of lithium carbonate were analyzed. This strategy, with significant advantages in terms of recovery efficiency, processing time, and energy consumption, provides a promising and sustainable alternative for the recycling of spent LIBs. [ABSTRACT FROM AUTHOR]
ISSN:0956053X
DOI:10.1016/j.wasman.2025.115295