Abstract

Pyrometallurgy is a popular industrial method that is employed in the recovery of valuable elements from black mass (BM), which is produced by pretreatment of Li-ion batteries. This method struggles with some downsides, such as the incineration of graphite and high energy consumption. In this study, the goal is to utilize graphite in the BM to produce a master alloy in an attempt to decrease the energy input requirement. To achieve this, metal oxides (Fe₂O₃ and CuO) are added to the BM to produce an Fe/Cu-based alloy containing Co/Ni as alloying elements. Mechanical activation is also employed to decrease the energy requirement and to increase the amount of metal oxide that can be reduced by the graphite in the BM. The results revealed that it is possible to produce the aforementioned alloys, the efficiency of which can be improved by applying mechanical activation. After 1 h of milling, the required heat flow for producing Fe- and Cu-based alloys is lowered for ~10 and ~25 kWh, respectively. Plus, the direct CO₂ emission decreases for 13–17% in the iron system and 43–46% in the copper system.