Selective Cobalt Precipitation for the Synthesis of Precursors for Cathode Materials of Li-Ion Batteries

Abstract

Due to the increase in energy storage for consumer electronics, stationary application and above all for electrical vehicles, the manufacturing of Li-ion batteries has dramatically increased in the past few years. Unfortunately, cathode materials still often use cobalt, and consequently, an increase of 10% per year of the world’s cobalt consumption has been observed. Li-ion batteries represent 60% of the use of extracted cobalt today (more than 80% expected in 2030), which is classified as a critical material since 2011 by the European Commission. Battery grade cobalt is produced by only few countries. 60% is provided by the Democratic Republic of Congo. In order to avoid reliance on cobalt supplying, European industry should have to develop alternative solution.We present here a new way to extract cobalt from a solution of battery-waste materials. Through a one-step process, it is possible to recover the cobalt, selectively, in a solution composed in majority of cobalt, nickel and manganese.The goal of the process is to form a cobalt-based Metal Organic Framework compounds (MOF) from a multi-metals based solution. The contact of a well-designed ligand with model multi-metallic solution of nickel, manganese and cobalt, under specific conditions, creates a precipitate, which is recovered by centrifugation or filtration. The XRD analysis of the resulting material demonstrates a crystalline structure, and its ICP analysis shows up to 99% of cobalt composition of the metallic nodes of the material. The same process with a real battery waste solution enables the formation of a precipitate made of 94% of cobalt (among the metallic centers).The resulting MOF can be used as a precursor for synthetizing cathode materials. In order to complete the described closed-loop concept, it is indeed possible to assemble a coin-cell from those products. The well define crystalline structure of the MOF makes them suitable for other industrial application, such as separation or catalysis (open-loop concept).We are focusing on better understanding of this selectivity process. Density Functional Theory (DFT) calculations are performed, as a tool to evaluate the energy of the different complexes in solution at all states of the nucleation and growth of the MOF. Moreover, the ligand used can form a MOF with each of the metals present in solution. Some nickel and manganese phases (more or less soluble) are involved during the process as a function of the reaction conditions. Identifying their nature and formation is another axis for the understanding of the presented work. Modelling these phenomena could help to determine the reaction that occurs, how the selectivity happens, and why the growing material is made of cobalt only (no other metal).