Abstract: The invention relates to a method of recycling lithium iron phosphate batteries with the aim of enabling the isolated recovery of elements from black mass. Black mass comprising at least cathodic and anodic components is immersed in a pH 13-14 solution to obtain a first leachate and first solid residue. The first leachate is immersed in a 4-6M acid solution to obtain a second leachate. The second leachate is passed through a first ion-exchange column where fluoride ions are retained and a second ion-exchange column where copper ions are to obtain a second eluate. The pH of the second eluate is adjusted to about 2.5-5 and a quantity of phosphoric acid that is sufficient to achieve an equivalent stoichiometric ratio of ferric iron and phosphate anions is added to obtain a first solution and an iron (III) phosphate precipitate. The first solution is combined with the first leachate to obtain a second solution. The pH of the second solution is adjusted to about 6.

Abstract: A method of treating a leaching solution derived from a black mass from spent lithium-ion batteries comprising setting pH of the leaching solution to about pH 1.2 to 2.5, adding iron powder to induce copper cementation, adding lime after copper cementation, and after adding lime, transiting pH of the leaching solution to about pH 6 to extract calcium fluoride, titanium hydroxide, aluminium hydroxide, iron hydroxide, and iron phosphate. A black mass recycling system comprising an impurity removal reactor configured to receive a sodium hydroxide feed, an iron powder feed, and a lime feed.

Abstract: A method of treating a leaching solution derived from a black mass from spent lithium-ion batteries comprising setting pH of the leaching solution to about pH 1.2 to 2.5, adding iron powder to induce copper cementation, adding lime after copper cementation, and after adding lime, transiting pH of the leaching solution to about pH 6 to extract calcium fluoride, titanium hydroxide, aluminium hydroxide, iron hydroxide, and iron phosphate. A black mass recycling system comprising an impurity removal reactor configured to receive a sodium hydroxide feed, an iron powder feed, and a lime feed.

Abstract: Systems and methods for recovering lithium (Li) from a lithium-ion battery waste stream including lithium sulfate (Li2SO4), sodium sulfate (Na2SO4), and water (H2O) are provided. The systems may include an evaporator unit with an optional heating system and a crystallizer unit downstream or upstream of the evaporator unit for cooling and solidifying sodium sulfate (Na2SO4). A lithium recovery unit is disposed downstream of the crystallizer unit or the evaporator unit that generates lithium carbonate (Li2CO3) product. Methods include evaporating a portion of water from the waste stream to generate water vapor and an effluent stream, which is then cooled to solidify sodium sulfate (Na2SO4) in a crystallizer vessel. The solid sodium sulfate (Na2SO4) is removed and the effluent stream is heated, followed by introducing sodium carbonate (Na2CO3) to produce lithium carbonate (Li2CO3) product, which is then recovered.

Abstract: Processes and systems for recovering metals from a lithium-ion battery waste stream include optionally conducting a leaching process to form a leachate stream, purifying the leachate stream in a first reactor to remove fluorine (F), phosphate (P), and one or more impurity metals selected from the group consisting of: copper (Cu), aluminum (Al), iron (Fe), and titanium (Ti), separating nickel (Ni), manganese (Mn), and cobalt (Co) from the purified filtrate liquid stream by passing the purified filtrate liquid stream into (i) a reactor for conducting a co-precipitation process by increasing pH or (ii) one or more chromatographic columns to generate an intermediate liquid stream comprising lithium (Li) and one or more recovered products comprising one or more of nickel (Ni), manganese (Mn), and cobalt (Co). The intermediate liquid stream can be introduced into a lithium precipitation reactor to precipitate at least one compound comprising lithium (Li).

Abstract: A method of treating a leaching solution derived from a black mass from spent lithium-ion batteries comprising setting pH of the leaching solution to about pH 1.2 to 2.5, adding iron powder to induce copper cementation, adding lime after copper cementation, and after adding lime, transiting pH of the leaching solution to about pH 6 to extract calcium fluoride, titanium hydroxide, aluminium hydroxide, iron hydroxide, and iron phosphate. A black mass recycling system comprising an impurity removal reactor configured to receive a sodium hydroxide feed, an iron powder feed, and a lime feed.