The growing demand for lithium calls for integrated strategies that combine resource recovery with sustainable material synthesis. Here, we demonstrate a patented chemicals-free circular approach that converts real spent lithium-ion battery black mass into functional lithium–aluminum layered double hydroxide (Li/Al-LDH). The process integrates a 5-min microwave-assisted carbothermic treatment, water-only leaching, and spontaneous precipitation, enabling the formation of crystalline Li/Al-LDHs alongside high-purity Li₂CO₃ without the use of added chemical reagents. Structural characterization by synchrotron pair distribution function analysis, XRD, and SEM confirms the formation of phase-pure LDHs with a hierarchical nanosheet-based morphology and an exceptionally high surface area (more than 400 m2 g−1). Preliminary adsorption–desorption experiments demonstrate the ability of the synthesized Li/Al-LDHs to reversibly exchange lithium ions, supporting their potential application as sorbents for lithium recovery from aqueous systems. The sustainability analysis reveals a reduction of 60%–90% in environmental impacts, including embodied energy and carbon footprint, compared to conventional LDH synthesis routes. This work establishes for the first time a direct link between battery recycling and lithium extraction technologies, providing a scalable pathway toward a circular and low-carbon lithium economy.
An Integrated Chemicals-Free Circular Model for Lithium Recovery From Spent Batteries to Direct Lithium Extraction From Brines
Mannu A.;Zanoletti A.;Cornelio A.;Zacco A.;Bianchi F.;Bontempi E.
2026-01-01
Abstract
The growing demand for lithium calls for integrated strategies that combine resource recovery with sustainable material synthesis. Here, we demonstrate a patented chemicals-free circular approach that converts real spent lithium-ion battery black mass into functional lithium–aluminum layered double hydroxide (Li/Al-LDH). The process integrates a 5-min microwave-assisted carbothermic treatment, water-only leaching, and spontaneous precipitation, enabling the formation of crystalline Li/Al-LDHs alongside high-purity Li₂CO₃ without the use of added chemical reagents. Structural characterization by synchrotron pair distribution function analysis, XRD, and SEM confirms the formation of phase-pure LDHs with a hierarchical nanosheet-based morphology and an exceptionally high surface area (more than 400 m2 g−1). Preliminary adsorption–desorption experiments demonstrate the ability of the synthesized Li/Al-LDHs to reversibly exchange lithium ions, supporting their potential application as sorbents for lithium recovery from aqueous systems. The sustainability analysis reveals a reduction of 60%–90% in environmental impacts, including embodied energy and carbon footprint, compared to conventional LDH synthesis routes. This work establishes for the first time a direct link between battery recycling and lithium extraction technologies, providing a scalable pathway toward a circular and low-carbon lithium economy.I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
