Evaluation of Filter Cake Washing Processes in Hydrometallurgical Battery Recycling of Lithium-Ion Batteries to Optimize Recoveries

Due to climate change, electromobility and thus lithium-ion batteries are attracting increased interest. With a simultaneous increase in demand for raw materials like Li, Ni, Co, and Mn, their hydrometallurgical recycling is also gaining attention. The associated recoveries must be improved due to EU regulations. In a lab scale, metals are lost to the wrong filter cakes after leaching, cementation, and precipitations. Therefore, this work investigates the question of how many wash steps are suitable after each process step to optimize the recoveries and purity of filter cakes by comparing a reference process and a process with extended washing. The comparison showed that it is possible to recover up to 3.5% of Ni, Co, and Mn by extended washing at each step and in total nearly 100% of Li if wash water is recirculated. An investigation of the substeps of washing demonstrated that single wash steps are able to recover from 0.5% to 3.5% of Ni, Co, and Mn and from 1.6% to 8.7% of Li. The impact of extended washing on purity is shown by the analysis of filter cakes, where the purity of Fe and Al could be improved by 43.0% and for Ni, Co, and Mn by 48.0%. The paper closes with recommendations on how many wash steps are suitable after each process step.