Carbothermal reduction between MOF-derived carbon and spent battery powder for metal recovery: Thermogravimetric behavior and kinetic analysis

Abstract

The combined hydrometallurgical and pyrometallurgical process is an innovative method for recycling spent batteries. This process includes a carbothermic reduction step that reduces the valence of valuable metals in the batteries, facilitating subsequent leaching, which is a crucial stage in the recycling process. Additionally, the use of new carbon materials in electrode materials for ternary lithium batteries, referred to as LIBs, is increasing. These materials typically have high porosity and a large specific surface area. In this study, two types of nanoporous carbon (NC) commonly used in electrodes, namely Al-PCP-800 and ZIF-8–800, were prepared to investigate their effects on the carbothermic reduction stage of recycling spent batteries. The carbothermal reduction reactions of spent LIBs powder mixed with activated carbon and the two types of NC were examined using a thermogravimetric balance (TG/DTG). Kinetic characteristics were calculated in the interval of maximum weight loss rate using five kinetic models: VM, RPM, URCM, KAS, and FWO. The kinetic analysis revealed that the KAS and FWO models, which exhibited higher correlation coefficients, more accurately described the carbothermic reduction reactions. TG analysis showed that the sample mixed with 25 % ZIF-8–800 achieved the lowest temperature at the weight loss peak for the maximum weight loss rate, 769°C at a heating rate of 20 °C/min. Additionally, the reaction activity of NC with the positive material in the spent LIBs powder was stronger than that of activated carbon. Among the models, the sample mixed with 25 % ZIF-8–800 exhibited the lowest activation energies, recorded at 171.83, 28.48, 122.22, 199.49, and 143.45 kJ/mol, respectively. XRD and XPS characterizations of the roasted products from the spent LIBs powder mixed with the three carbon materials at various roasting end temperatures demonstrated that the cathode materials initially decomposed into Mn3O4, NiO, CoO, Li2O, and Li2CO3. At higher temperatures, Mn3O4, NiO, and CoO were further reduced to MnO, pure metallic Co, and pure metallic Ni, respectively. The sample mixed with ZIF-8–800 showed the most substantial reduction of metallic elements, with the relative contents of pure metallic Ni, pure metallic Co, and low-valent Mn elements reaching 5.50 %, 4.41 %, and 71.29 %, respectively, at a final roasting temperature of 800 °C. Therefore, NC demonstrated greater reactivity in the reduction reactions with the cathode material in the spent LIBs powder, ranking in the order of ZIF-8–800 > Al-PCP-800 > activated carbon.