KazNU Scientists Develop Environmentally Safe Technology for Extracting Valuable Components from Spent Lithium-Ion Batteries

By 2050, global electric vehicle production is expected to exceed 100 million units, significantly increasing demand for lithium-ion batteries (LIBs) and the volume of spent batteries requiring disposal. Spent LIBs contain toxic and environmentally hazardous components - flammable electrolytes, heavy metals, and materials prone to spontaneous combustion if the casing is damaged. At the same time, they represent a valuable source of rare and expensive metals - lithium, cobalt, nickel, and manganese - whose natural reserves are limited and concentrated in a handful of countries.

In Kazakhstan, battery collection culture remains underdeveloped - the share of recycled household waste does not exceed 18%, and the capacity of two pilot plants opened in 2024 (740 tons per year) is disproportionate to the volume of spent power sources being generated. The program's goal is to conduct applied research on environmentally safe extraction of valuable components from spent lithium batteries using mechanochemical, sonochemical, electrochemical, hydrochemical, and solvochemical methods, along with developing a cost-effective technology and a pilot plant.

The program comprises nine tasks: establishing a culture of battery collection and recycling in Kazakhstan; developing methods for safe disassembly and sorting of different battery types; creating a testing procedure for batteries suitable for reuse; developing a facility for safe battery discharge; creating methods for processing components via self-propagating high-temperature synthesis (SHS) in a flow reactor; developing mechanical activation modes using a planetary mill and attritor; creating a method for direct regeneration of cathode materials; determining the thermodynamic and kinetic parameters of leaching; and developing a pilot plant with a capacity of 200 kg of batteries per day.

The research employs an automated sorting line with an X-ray detector, an electrochemical cycling station, a saline discharge technology, an SHS reactor, and leaching methods using inorganic (HCl, HNO3, H2SO4) and organic (citric, malic, oxalic) acids. Metal extraction relies on extractants such as D2EHPA and Cyanex 272, along with activated carbon sorbents derived from coconut shells and apricot pits. The program is led by Dr. Fedor Malchik, PhD, associate professor and specialist in lithium-ion and metal-ion batteries, who served as lead researcher on a General Motors-funded project on silicon anodes, with Professor Netanel Shpigel serving as international co-supervisor.

Spanning 26 months (November 2024 - December 2026), the program aligns with the "Kazakhstan-2050" strategy and the Environmental Code of the Republic of Kazakhstan, creating new jobs and reducing dependence on lithium, cobalt, and nickel imports, while strengthening Kazakhstan's position as a leader in green technologies and sustainable development.