Greener method recovers critical metals from spent batteries

Researchers have developed a method to recover high-purity nickel, cobalt, manganese and lithium from spent lithium-ion batteries using a mild, sustainable solvent.

The researchers from Monash University said the process provides a safer and more environmentally friendly alternative to traditional high-temperature or chemical-intensive recycling methods.

Current recovery methods are often limited, relying on high temperatures or hazardous chemicals to extract only some elements.

The Monash team’s new method addresses these challenges by using a novel deep eutectic solvent (DES) combined with an integrated chemical and electrochemical leaching process.

Dr Parama Chakraborty Banerjee, principal supervisor and project lead, from the Department of Chemical and Biological Engineering, said the approach achieves more than 95% recovery of nickel, cobalt, manganese and lithium even from industrial-grade “black mass”, which contains mixed battery chemistries and common impurities like graphite, aluminium and copper.

“This is the first report of selective recovery of high-purity Ni, Co, Mn and Li from spent battery waste using a mild solvent,” Banerjee said.

“Our process not only provides a safer, greener alternative for recycling lithium-ion batteries but also opens pathways to recover valuable metals from other electronic wastes and mine tailings.”

Parisa Biniaz, PhD student and co-author, said the breakthrough is a major step closer to a circular economy for critical metals and reduces the environmental impact of battery disposal.

“Our integrated process allows high selectivity and recovery even from complex, mixed battery black mass. The research demonstrates a promising approach for industrial-scale recycling, recovering critical metals efficiently while minimising environmental harm,” Biniaz said.

Read the full research paper here.

Image caption: PhD student Parisa Biniaz and Dr Parama Banerjee in the lab, where the Monash team developed a greener method to recover critical metals from spent lithium-ion batteries. Image: Supplied