Experimental study and modeling of the impact of black mass chemical and morphological heterogeneity on critical metal recovery

Lithium-ion batteries are essential for electric vehicles and stationary energy storage and play a pivotal role in the energy and ecological transition. These materials, which include critical and strategic metals such as lithium, nickel, cobalt, and copper, are in high demand, with supply chains heavily reliant on imports. To ensure industrial sovereignty and reduce environmental impact, the European Union imposes circularity, making recycling indispensable.
The black mass, a powder derived from dismantling and shredding end-of-life batteries, is rich in valuable metals. However, due to its chemical and morphological heterogeneity, which evolves with battery type and pre-treatment processes, it is difficult to process. Hydrometallurgical recycling, which consists of metal leaching as the first step followed by subsequent separation and extraction steps, is preferred due to its low energy demands and high recovery rates. In this context, leaching is a key step; however, the interactions between acids, reductants, and metallic phases are not yet fully understood. Factors such as particle size, porosity, and phase accessibility further complicate predictions and process optimization. 
To address these challenges, this project proposes a multidisciplinary approach combining experimentation and modeling. This methodology is structured into three stages: (1) an in-depth characterization of black mass using advanced techniques (ICP, Raman spectroscopy coupled with morphological analysis); (2) systematic leaching tests to identify limiting mechanisms; and (3) the development of a thermokinetic model integrating chemical and morphological heterogeneity to optimize processes.
The project's outcomes include a better understanding of coupled chemical and physical leaching mechanisms and the development of a predictive tool for process optimization. This methodology could be extended to other strategic recycling areas, such as catalysts, with the aim of advancing a resilient and sustainable circular economy.

Keywords: battery recycling, hydrometallurgy, kinetic and thermodynamic modelling

• Academic supervisor    Dr. Laurent CASSAYRE, LGC UMR5503, ORCID : 0000-0001-6876-6086
• Doctoral School    ED468 MEGeP, INP Toulouse
• IFPEN supervisor    Dr. Madina NAUKANOVA, ORCID: 0000-0002-8514-0664
• PhD location    IFPEN, Lyon, France and Chemical Engineering Laboratory (LGC), Toulouse, France
• Duration and start date    3 years, starting in the fourth quarter 2026 (Novembre 2)
• Employer    IFPEN
• Academic requirements    University master’s degree in chemical or process engineering or in chemistry
• Language requirements    English level B2 (CEFR)
• Other requirements    Kinetic and thermodynamic modelling skills

To apply, please send your cover letter and CV to the IFPEN supervisor indicated here below.