Abstract: A method for recycling All solid state batteries (ASSBs), the method including: receiving a recycling stream of ASSBs comprising an electrolyte comingled with at least one charge material; introducing a passivating substance for neutralizing an undesired reaction or discharge of the charge materials from the batteries defining the recycling stream; agitating the batteries in the recycling stream in the presence of the passivating substance for liberating the charge materials and electrolyte stored therein; and recovering the charge material and the electrolyte from the agitated batteries, and such that the passivating substance combines with the agitated batteries for generating a beneficial product thereby recycling ASSBs.

Abstract: Recycling of nickel-metal hydride (NiMH) batteries extracts substantially pure nickel based on adding a leach agent to granular cathode material resulting from agitation of the NiMH batteries to form a leach solution. A pH of the leach solution is maintained for precipitating iron, aluminum and lanthanide rare earth elements (REE) for yielding a nickel solution for forming a cathode material precursor in a recycled battery, often with a high nickel content.

Abstract: A process to make battery-grade graphite from black mass. The process entails spheronizing graphite derived from black mass to yield spheronized graphite, classifying the spheronized graphite to remove conductive carbon fines, and optionally coating the resulting bulk graphite to reduce its specific surface area.

Abstract: A method for recycling anode materials from a comingled recycling stream derived from exhausted Li ion batteries includes receiving a precipitate quantity remaining from a cathode recycling stream. This precipitate is almost exclusively graphite used for the anode material in the recycled batteries. The precipitate results from an acid leach of charge material from the lithium battery recycling stream. A strong acid is added to the precipitate for removal of residual cathode and separator materials and the mixture heated. The strong acid removes residual aluminum oxide from the separator by transformation to aluminum sulfate. Washing the acid treated precipitate removes water soluble contaminants, such as the aluminum sulfate reacted from the aluminum oxide and sulfuric acid, to generate substantially pure graphite. Any residual material remaining from the cathode recycling phase is also removed.

Abstract: A method to recycle graphite from lithium and sodium-ion batteries. Graphite from the batteries first is treated in an aqueous solution of strong base at a temperature range between about 100° C. and about 250° C., a pressure range between about 0.9 bar and about 20 bar, at a solid-to-liquid ratio of from about 1-to-1 to about 1-to-4. The treated graphite is then washed, filtered, and then treated with a mineral acid (e.g., hydrochloric acid). The purified graphite is then coated with amorphous carbon at a weight percentage range between 0.5 wt % and about 20 wt %. The recycled graphite yielded by the method routinely achieves a purity >99.9%, a specific area of less than or equal to about 10 m2/g.

Abstract: The inventions described herein provide methods and systems for recycling lithium iron phosphate batteries, including: adding an oxidizing agent to a recycling stream of lithium iron phosphate (LiFePO4) batteries to form a leach solution; filtering the leach solution to remove a residue and obtain a lithium rich solution; modifying pH of the lithium rich solution for filtering impurities and obtaining a purified Li solution; and adding a precipitant to the purified Li solution thereby precipitating a lithium compound.

Abstract: A battery recycling process recovers lithium from nickel-rich cathode material in a recycling stream of end-of-life batteries. A dilute acid leach of a high nickel content cathode material contains a mixture of sulfuric acid based on a molar quantity of lithium in the cathode material. The highly selective leach generates a lithium rich solution with a small amount of nickel removable by nanofiltration to achieve a highly efficient recovery of the lithium contained in the recycling stream. A quantity of the leach acid based on the lithium content and a quantity of water based on a total black mass of the recycling stream results in a highly selective, near pure lithium leach when the recycling stream results from high nickel NMC batteries such as 811.