Electroslag Refining (ESR) for High-Purity Recovery of Critical Metals from Spent Lithium-Ion Batteries: A Supplementary Approach to Traditional Recycling Methods

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This is a In Vitro Study study.

Sudhakar Geruganti

doi:10.31224/5030

August 11, 2025Open Access

Electroslag Refining (ESR) for High-Purity Recovery of Critical Metals from Spent Lithium-Ion Batteries: A Supplementary Approach to Traditional Recycling Methods

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Key Points

Electroslag refining achieves 99.98% purity of cobalt, nickel, and copper from spent lithium-ion batteries, improving economic viability.
Experimental data indicates a 92% reduction in impurities for cobalt compared to traditional smelting methods.
The proposed hybrid 'Pyro-ESR-Hydro' model combines pyrometallurgy and hydrometallurgy for optimal recovery efficiency.
Techno-economic analysis shows a 15-20% cost increase over hydrometallurgy alone, indicating its suitability for premium applications.

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Implication

Exploration of electroslag refining improves cobalt, nickel, and copper recovery in lithium-ion batteries, suggesting a new hybrid model for efficiency.

Abstract

While hydrometallurgy dominates lithium-ion battery (LIB) recycling, this paper explores the niche but critical role of Electroslag Refining (ESR) in recovering ultra-high-purity cobalt, nickel, and copper from pyrometallurgically processed LIB waste. We demonstrate that ESR can upgrade impure Co-Ni-Fe alloys (from smelting) to 99.98% purity, meeting cathode-grade specifications, though it remains unsuitable for lithium recovery. A hybrid "Pyro-ESR-Hydro" model is proposed, where ESR bridges pyrometallurgy and hydrometallurgy, optimizing both metal purity and lithium yield. Experimental data shows ESR reduces sulfur/oxygen impurities in recovered Co by 92% compared to conventional smelting, while techno-economic analysis reveals a 15–20% cost premium over standalone hydrometallurgy, justified for premium battery applications.

Electroslag Refining (ESR) for High-Purity Recovery of Critical Metals from Spent Lithium-Ion Batteries: A Supplementary Approach to Traditional Recycling Methods

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Electroslag Refining (ESR) for High-Purity Recovery of Critical Metals from Spent Lithium-Ion Batteries: A Supplementary Approach to Traditional Recycling Methods

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