Black Mass: The Key to Closing the Loop

We find ourselves at a point in history where we must make new and more innovative choices. We can no longer operate under old ways of thought when it comes to resource consumption. Our planet's resources are depleting and we must find ways to maximize our usage and reduce the demand for more. When considering the significant impact that mining of raw materials and the production of lithium-ion batteries has on the earth, we must find a way to minimize the negative environmental impact and lower the overall CO2 footprint of the battery. This can be done through utilizing the battery to its fullest in a 2nd-life application after the initial life in an e-vehicle. It can also be done through responsible recycling at the battery's end-of-life. A variety of recycling processes exist, many of which focus on extracting Black Mass, making this substance essential for the recovery of valuable resources.

What is Black Mass?

Let's begin with defining what black mass actually is.

Black Mass is a black powder recovered through various recycling processes, consisting primarily of the cathode and anode materials of the battery. In addition to lithium, it often contains other valuable metals, particularly nickel and cobalt. These raw materials, in addition to other essential elements are used to manufacture new lithium-ion batteries.

The process of obtaining these remaining raw materials is complex, but necessary in closing the loop when we speak of battery circularity. The following five steps illustrate one common process for converting end-of-life batteries into Black Mass followed by the extraction of remaining raw materials, which are then prepared for reuse in new batteries.

End-of-life batteries are collected, dismantled, and deactivated - The dismantling process for batteries varies based on their construction. It generally involves opening the pack, removing all wiring and electronics, and further disassembling and extracting components down to the module or cell level. For safety reasons, and to avoid electrical currents during shredding, batteries are in most cases deactivated or fully deep discharged as early as possible. 

Shredding - The dismantled battery components are then crushed and shredded into smaller pieces. This step helps to break down the materials and prepare them for further processing.

Separation - After crushing, the material is subjected to various separation techniques to segregate the different components. Methods like mechanical separation and magnetic separation are commonly used to isolate metals from other materials. Thermal treatment to extract binders or electrolytes, often takes place as well.

Extraction of Black Mass - The fine powder that results from these processes is what we refer to as black mass.

Material Extraction - The metals recovered from the black mass are further refined to achieve the desired purity levels. These refined metals can then be reused in the production of new lithium-ion batteries. Separation is typically followed by material extraction using metallurgical methods. This extraction is carried out either through hydrometallurgy alone or through a combination of pyrometallurgy and hydrometallurgy. Pyrometallurgyinvolves heating the material in a furnace where chemical reactions occur to separate the desired metals from the Black Mass, resulting in the formation of an alloy and a slag. Hydrometallurgy employs chemical processes such as leaching, precipitation, solvent extraction, and purification to extract valuable metals from Black Mass. The end products are often metal salts, which can be utilized in the production of new batteries. For instance, lithium is typically precipitated from the solution as lithium carbonate. 

The extraction and recycling of black mass are important for several reasons:

• Environmental Benefits: If not done properly, the recycling of lithium-ion batteries can cause environmental hazards, such as soil and water contamination from toxic substances. Responsible recycling of lithium-ion batteries and black mass helps to minimize these hazards. 

• Resource Efficiency: Recycling black mass reduces the need for the mining of new raw materials. This conserves natural resources and reduces environmental impact of mining.
• Economic Value: Black mass consists of valuable materials including lithium, manganese, cobalt, and nickel. By recovering these raw materials, a true circular battery economy can begin to take shape. 

Circunomics helps in the process by allowing black mass to be traded through our marketplace. The mission at Circunomics is to connect buyers and recyclers with these valuable resources.  Black mass is indeed a key component in achieving a true circular battery economy.

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