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<p>Lithium-ion batteries (LIBs) have become the primary energy storage solution for the new energy industry. Efficient and environmentally friendly recycling of valuable metals from spent LIBs is crucial for mitigating environmental pollution and ensuring resource sustainability. This study proposes a clean process combining in situ carbothermal reduction with wet magnetic separation to recover valuable metals from spent LIBs. Thermodynamic calculations and experimental results confirmed that cathode materials (LiNi<sub>x</sub>Co<sub>y</sub>Mn<sub>(1-x–y)</sub>O<sub>2</sub>) can be reduced and decomposed by anode graphite to form Fe–Ni–Co alloy, Li<sub>2</sub>CO<sub>3</sub> or Li<sub>2</sub>O, and MnO. These products were effectively separated and enriched into magnetic concentrate, selective leaching solution, and non-magnetic slag, respectively. Under optimal conditions—carbothermal reduction at 1000&#xa0;°C for 120&#xa0;min, followed by wet magnetic separation at 70&#xa0;°C with 18.3 wt% sulfuric acid, liquid-to-solid ratio of 15:1, and 60&#xa0;min—the recovery rates of Ni, Co, and Li reached 96.8%, 96.2%, and 93.3%, respectively. The magnetic concentrate and non-magnetic slag can serve as raw materials for producing nickel/cobalt sulfate and as a reducing agent in metallurgy, respectively. Lithium carbonate obtained from the leaching solution exhibited a purity of 99.70%. This study provides a clean and efficient strategy for recycling valuable metals from spent LIBs.</p> Graphical Abstract <p></p>

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Selective Recovery of Valuable Metals from Spent Lithium Nickel Manganese Cobalt (NMC) Batteries by Carbothermal Reduction and Wet Magnetic Separation Process

  • 期刊论文

  • 发表日期：

    2026年3月26日

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  • Xiaoyan Xiang,
  • Yiming Sun,
  • Yanfang Wei,
  • Jianguo Yin,
  • Juan An

摘要

Lithium-ion batteries (LIBs) have become the primary energy storage solution for the new energy industry. Efficient and environmentally friendly recycling of valuable metals from spent LIBs is crucial for mitigating environmental pollution and ensuring resource sustainability. This study proposes a clean process combining in situ carbothermal reduction with wet magnetic separation to recover valuable metals from spent LIBs. Thermodynamic calculations and experimental results confirmed that cathode materials (LiNixCoyMn(1-x–y)O2) can be reduced and decomposed by anode graphite to form Fe–Ni–Co alloy, Li2CO3 or Li2O, and MnO. These products were effectively separated and enriched into magnetic concentrate, selective leaching solution, and non-magnetic slag, respectively. Under optimal conditions—carbothermal reduction at 1000 °C for 120 min, followed by wet magnetic separation at 70 °C with 18.3 wt% sulfuric acid, liquid-to-solid ratio of 15:1, and 60 min—the recovery rates of Ni, Co, and Li reached 96.8%, 96.2%, and 93.3%, respectively. The magnetic concentrate and non-magnetic slag can serve as raw materials for producing nickel/cobalt sulfate and as a reducing agent in metallurgy, respectively. Lithium carbonate obtained from the leaching solution exhibited a purity of 99.70%. This study provides a clean and efficient strategy for recycling valuable metals from spent LIBs.

Graphical Abstract