Green Chemistry and Zero Liquid Discharge Process for Complete Recovery of Lithium, Cobalt, Manganese, and Nickel from Lithium-Ion Battery Cathodes

This chapter explores an innovative green chemistry hydrometallurgical process for recycling lithium-ion battery cathodes, focusing on the recovery of lithium, cobalt, manganese, and nickel. The process uses formic acid leaching to produce formate salts, which are then converted into high-purity lithium carbonate and mixed metal sulfates suitable for new battery production. Key topics include the optimization of leaching conditions, the kinetics of the leaching process, and the elimination of toxic reagents and waste. The process achieves high recovery rates and produces sodium-free lithium carbonate, making it a sustainable and economically viable solution for battery recycling. The chapter also details the materials and methods used, including the analysis of virgin NCM111 powder and the conditions for formic acid leaching. The results highlight the efficiency and environmental benefits of this process, offering a promising alternative to conventional recycling methods.