Exploration of physical recovery techniques and economic viability for retired lithium nickel cobalt manganese oxide-type lithium-ion power batteries

Retired lithium nickel cobalt manganese oxide-type lithium-ion power batteries (NCMs) pose considerable challenges for recycling due to high contamination levels and low efficiency in the recovery process. Despite these complexities, NCMs contain significant amounts of precious metals, making them a substantial untapped resource with immense recycling potential. This study optimizes heat treatment conditions for NCMs focusing on cathode materials and the current collector. The optimal parameters of 280 °C, 2 h, and 60 s were identified through systematic discharge, disassembly, crushing, and sorting processes. Precious metal recovery rates exceeded 90%. Thermogravimetric-thermal differential analysis at 400 °C revealed the complete removal of bonding agents between the electrode materials. A comprehensive cost analysis was conducted using a mathematical model for retired power batteries revenue, scrutinizing the consumption costs and benefits of pyrometallurgical, hydrometallurgical, and physical recovery processes for NCMs. The input–output efficiencies were 6.56%, 28%, and 23%, respectively. This study supports the viability of physical recycling for a future mechanical–chemical combination approach to reduce production costs and environmental impacts. The proposed method holds economic, environmental, and industrial development value and provides a guide for sustainable recycling practices in the lithium-ion battery industry.