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Received August 27, 2025
Revised February 12, 2026
Accepted February 27, 2026
Available online July 25, 2026
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Assessment of Metallic Reductants in the Processing of Cathode Materials from Spent Lithium-Ion Batteries: Emphasis on Aqueous and Non-aqueous Leaching Processes

Resources Recycling, University of Science and Technology (UST) 1Resources Utilization Division, Korea Institute of Geoscience and Mineral Resources (KIGAM) 2Materials Recycling Group, Applied Materials Division, Argonne National Laboratory
kkurniawan@anl.gov, skkim@kigam.re.kr
Korean Journal of Chemical Engineering, July 2026, 43(9), 2427-2442(16)
https://doi.org/10.1007/s11814-026-00691-6

Abstract

Leaching is a critical step in the recycling of cathode materials, such as lithium cobalt oxide (LCO) and nickel-cobaltmanganese

(NCM) oxide, from spent lithium-ion batteries (LIBs). Conventional processes typically use aqueous mineral 

acids with hydrogen peroxide (H2O2) as a reductant. Recently, there is a growing attention on the development of nonaqueous

leaching, which works by replacing water-based lixiviants with non-aqueous/water-limited systems, such as 

acidic organic extractants dissolved in non-polar diluents like kerosene. Metallic reductants (e.g., Cu and Al) are attractive 

alternatives to H2O2, with potential for co-recovery of reductant metals and improved transport and handling. This study 

evaluates the effectiveness of metallic reductants (Cu, Al, Ni, Mn, Fe, and Zn) in the leaching of cathode materials (LCO 

and NCM) under both aqueous and non-aqueous leaching systems. In aqueous leaching (using H2SO4), all the tested 

metallic reductants demonstrated effectiveness in advancing the leaching of cathode materials, and their performance was 

influenced by three key factors: (i) redox reactions, (ii) hydrogen gas (H2) formation, and (iii) cementation processes. In 

contrast, non-aqueous leaching exhibited a more complex mechanism, with Cu identified as the only effective reductant. 

This result prompted the proposal of leaching equilibria specific to the non-aqueous system. The study further investigated 

the effects of several parameters, including the mass ratio of metal reductant to cathode material, the presence of graphite, 

and, in the case of non-aqueous leaching, the impact of water addition and the choice of organic extractants.

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