Recycling method for treating used batteries, in particular rechargeable batteries, and battery processing installation

Abstract

Abstract The invention relates to a method for treating used lithium batteries (10) contain- ing the steps: comminuting the batteries (10) such that comminuted material (24) is obtained, and (b) inactivating of the comminuted material (24) such that an inactive comminuted material (42) is obtained. According to the invention, the drying is conducted at a maximum pressure of 300 hPa and a maximum temper- ature of 80 °C and the deactivated comminuted material (42) is not filled into a transport container and / or said deactivated comminuted material is immediately further processed after the drying process. Abstract The invention relates to a method for treating used lithium batteries (10) contain- ing the steps: comminuting the batteries (10) such that comminuted material (24) is obtained, and (b) inactivating of the comminuted material (24) such that an inactive comminuted material (42) is obtained. According to the invention, the drying is conducted at a maximum pressure of 300 hPa and a maximum temper- ature of 80 °C and the deactivated comminuted material (42) is not filled into a transport container and / or said deactivated comminuted material is immediately further processed after the drying process. 20 24 27 86 42 19 D ec 2 02 4 2 0 2 4 2 7 8 6 4 2 1 9 D e c 2 0 2 4

Description

The battery processing installation may have a combustion device for the thermal or catalytic combustion of gaseous components of the electrolyte. This is preferably arranged behind the condenser in the direction of material flow and / or in front of an exhaust outlet. This means that no components of the electrolyte are released through the exhaust outlet into the atmosphere. The battery processing installation preferably comprises a particle removal device for removing particles from the gas flow that is drawn out of the drying device. The particle removal device may comprise, for example, a cyclone and / or a filter and / or activated carbon. In the following, the invention will be explained in more detail by way of the attached drawings. They show Figure 1    a flow diagram of a method according to the invention, Figure 2    a cross-section through a battery processing installation according to the invention and 25 Figure 3 a cross-section through further optional components of a battery processing installation according to the invention. Figure 4 shows a flow diagram of a method according to the invention ac-30              cording to a second embodiment. Figure 1 shows a flow diagram of a method according to the invention. Batteries 10.1, 10.2, ..., in particular battery systems made up of several battery modules or battery stacks, which are in turn made up of several battery cells, are initially 2024278642   19 Dec 2024 ■ 20 discharged in a discharge unit 12. This is followed by the dismantling of the batteries 10 at a dismantling station 14, if this is necessary because the battery systems cannot otherwise be delivered into the comminution unit for geometric or gravimetric reasons. In order to do this, the battery systems are opened and dismantled to the point at which the modules / stacks can be individually removed. If required, the cells can also be separated from the drive electronics. The resulting sub-units (modules / stacks) and / or cells 16.1, 16.2, ... are fed into a comminution unit 18, which comprises, for example, a rotary shear with a rotor and a comminutor with stators or several rotors, or a cutting mill with a rotor and several rotors. The comminution unit 18 comminutes the batteries 10 under shielding gas 20, which is extracted, for example, from a shielding gas cylinder. Alternatively or additionally, liquid nitrogen from a liquid nitrogen source 19 may be may be injected. The shielding gas may refer, for example, to nitrogen, a noble gas, carbon dioxide, nitrous oxide or another gas which is preferably not toxic. Comminuted material 24 is produced during the comminuting; the material is fed into an inactivation device in the form of a drying device 26. An airlock 28 is arranged between the comminution unit 18 and the drying device 26, the airlock being so gas-tight that the pressure device 26 is - to a good approximation -separated from the comminution unit 18 so as to be gas-tight. The drying device 26 is connected to a vacuum installation 29 that comprises a 25 vacuum pump 30 and creates a vacuum. A pressure p26 from p26 ~ 100 hPa, at times below 50 hPa, is present in the drying device 26. It should be noted that, within the scope of the present description, the vacuum pump should be understood particularly generally to mean a device that creates a vacuum. It is possible and preferred, but not necessary, for the vacuum pump to simultaneously 30 work as a compressor, such that gas is emitted from it under a pressure that is greater than the ambient pressure. In the case depicted in figure 1, the vacuum pump is a compressor which sucks 2024278642   19 Dec 2024 ■ 20 in and compresses gas 31 that is present in the drying device 26. Alternatively or additionally, the vacuum installation 29 may have a jet pump which uses a blasting medium in the form of a liquid that is conducted at a high speed through Venturi nozzles. The blasting medium is alkaline and has a pH value of at least pH 1 and is, for example, a 10% potassium hydroxide solution. The vacuum installation 29 comprises a gas purification device 32 that is arranged between the drying device 26 and the vacuum pump 30, and which has a condenser 34 and / or an activated carbon filter 36 in the present case. The condenser is operated at a temperature of -10°C so that dimethyl carbonate and ethyl methyl carbonate condense and can be dispensed into a condensate container 38. In addition, any water present is separated by freezing. A control valve 40 is designed to open when the pressure p26 becomes too great and to close when the pump circuit and drying container are to be decoupled. The drying material is preferably moved during drying. This may be achieved via agitating with an agitator 41, such as an anchor agitator or a rod agitator with rods arranged perpendicular to the agitator shaft. Alternatively, it can be achieved by way of a drying container that is moved. The drying of the comminuted material results in deactivated comminuted material 42, which is fed into a filling device 44. A transport container 46 is then filled with the deactivated comminuted material 42 under vacuum and / or shielding gas. The transport container 46 is preferably gas-tight. It is possible, but not 25 necessary, for the transport container 46 to be filled with inert gas prior to transportation such that it is under normal pressure. Alternatively, it is also possible for the transport container to be sealed under vacuum and transported. It is possible that, instead of the transport container, a vacuum-sealed foil is selected, such as an aluminium compound foil. 30 The comminution unit 18 is fed with shielding gas 20 from the vacuum pump 30 via a flushing line 48. If the vacuum pump 30 also functions as a compressor -as in the present case - which represents a preferred embodiment, the shielding 2024278642   19 Dec 2024 ■ 20 gas can be drawn over a pressurised gas cylinder 50. Alternatively or additionally, the shielding gas 20 can be given off into the surroundings, following additional cleaning if necessary. Figure 2 schematically depicts a cross-section through a battery processing installation 52 according to the invention (see figure 1), which comprises a standard container 54 in which the comminution unit 18, the drying device 26 and the filling device 44 are arranged. A first gas-tight conveyor 56 is arranged behind the comminution unit 18; the conveyor comprises, for example, a screw conveyor or a tube chain conveyor. The first conveyor 56 delivers the comminuted material 24 to the drying device 26, which is connected to the vacuum generation device, not depicted in figure 2. A second conveyor 58 is arranged behind the drying device 26 in the direction of material flow; preferably, the conveyor is also designed to be gas-tight and may include a screw conveyor or a tube chain conveyor. The second conveyor delivers the inactivated comminuted material 42 to the filling device 44. Figure 3 depicts optional units - available in the present embodiment - of the battery processing installation 52 according to the invention (see figure 1) which comprise a breakdown comminutor 60, as well as a separator 62. The breakdown comminutor 60 contains a transport container draining device 64, by means of which inactivated comminuted material 42 can be removed from the transport container 46. The breakdown comminutor 60 produces breakdown material 66, which is fed into the separator 62. The separator may refer, for exam-25 ple, to a zigzag separator. The battery processing installation 52 preferably comprises a comminutor, which is preferably situated in the material flow in front of the classification device 74 and includes a rapid comminution tool, wherein a peripheral speed of the rotor is 30 greater than 1 m / s, preferably greater than 10 m / s. This comminutor comminutes the comminuted material and subjects it to such mechanical stress that the electrochemically active coating at least partially detaches from the carrier. The presence of such a comminutor is a generally preferred feature of a battery pro- 2024278642   19 Dec 2024 ■ 20 cessing installation according to the invention. A light fraction with a separator foil and fine coating material, and a heavy material fraction with carrier foils (aluminium and copper) with an easy-adhesive coating occur in the separator. Both fractions are each placed on a sieve for further separation into coating and separator foil, or coating and metal foil. The further processing of the resulting fractions is conducted separately. The breakdown material 66 is fed to the separator 62 by means of a third conveyor 68. A fourth conveyor 70 guides sifted material 72, in particular the material of the light fraction and the material of the heavy fraction, which leaves the separator 62, into one or two classification devices 74. The classification device 74 preferably has an air jet sieve, which simultaneously functions as a separation device in the case of the heavy fraction for separating the active material from the carrier. In the case of the light fraction, the active material is separated by the separator. The separation results in an active material fraction 76, with which a transport container 78 is filled. In addition, a carrier fraction (heavy material) 80 and a separator fraction (light material) are produced, which - in the present embodiment - are fed into a filling unit 84 using a fifth conveyor 82; the filling unit fills a container 86 with the carrier fraction 80. The filling unit 84 comes together with a second filling unit 88 to form part of a second filling device. 25 Figure 4 depicts a flow diagram of a second battery processing installation 52 according to the invention, which has two drying devices 26.1, 26.2. Each drying device 26.1, 26.2 has an agitator 41.1 or 41.2. The airlock 27 is located in front of the comminution unit 18 in the flow of material direction, wherein the airlock is designed as a rotary airlock in the present case and can be used to fill the com-30 minution unit 18 without the gas atmosphere in the comminutor mixing with the surrounding air. The airlock 28 is located behind the comminution unit 18 in the direction of material flow, wherein the airlock is designed as a rotary airlock in the present case and can be used to feed the drying devices 26.1, 26.2 one-by- 2024278642   19 Dec 2024 ■ 20 one or simultaneously. Each agitator 41.1, 41.2 has a power output of at least 4 kW, in the present case 5 kW, per cubic metre of drying volume. The mechanical energy that is introduced is transferred to the comminuted material 24 contained in the respective drying device 26.1, 26.2. Part of the mechanical energy leads to the separation of components of the comminuted material, for example to a separation of coating material from the carrier foil. However, the mechanical output is largely converted into thermal energy. This thermal energy is absorbed by the vaporising electrolyte, which is still a component of the comminuted material 24. The gases that develop in the drying devices 26.1 (i = 1, 2) are first cleaned of particles that have been picked up; this is done by means of a particle removal device 90. The particles are collected in a container 92 or immediately processed further. The particle removal device 90 may refer, for example, to a filter and / or a cyclone. The vacuum pump 30 is arranged behind the particle removal device 90 in the direction of flow. It is beneficial if at least a second pump of a different design is arranged behind or parallel to the vacuum pump 30 in the direction of gas flow. The condenser 34, in which a pressure p34 is present, is arranged behind the vacuum pump 30. For the most part, the pressure p34 corresponds to the ambient pressure, i.e. it deviates from the ambient pressure by a maximum of 100 25 hPa, for instance. Given that the pressure p34 is considerably greater than the pressure p26 in the drying devices 26.1, 26.2, the carboxylic acids in particular, especially dimethyl carbonate, propylene carbonate, diethyl carbonate, ethylene carbonate and ethyl methyl carbonate, condense. The resulting condensation heat is discharged by cooling. In this situation, it is possible that the condenser 30 is cooled to a temperature of T34, which differs from the ambient temperature TUmg by less than 20 Kelvin. This has the advantage that the amount of energy required for drying the comminuted material 24 is comparatively low and a lot of electrolyte can be recovered at the same time. 2024278642   19 Dec 2024 ■ 20 An activated carbon filter 36 may be arranged behind the condenser 34 in the direction of material flow; however, this is not necessary. It is also possible for an oxidation device 94 to be arranged behind the condenser 34 in the direction of flow, by means of which the remaining oxidisable material, especially from organic components of the electrolyte, are oxidised either catalytically or thermally such that the gas leaving the oxidation device 94 can be safely released into the atmosphere. It is possible for the battery processing installation 52 to comprise a filling device 44, by means of which a transport container 46 can be filled with the dried comminuted material 24 in the form of the inactive comminuted material 42. However, it is also possible that the battery processing installation 52 does not have such a filling device 44. The drying devices 26.1, 26.2 (it is also possible that the battery processing installation only has one drying device 26 in this embodiment) each comprise an exit airlock 96.1, 96.2 in the form of a rotary and deflection airlock. The inactive comminuted material 42 is temporarily stored, for example, in a silo 98 or directly fed into a heavy material separator 100. The heavy material separator 100 is designed to separate material with a density of at least 2.6 grams per cubic centimetre, particularly aluminium and / or iron components. The remaining material is subsequently comminuted further in a comminutor 102 25 and then classified in a separator 62 into light material 108 (separator and coating material) and heavy material 110 (carrier foils and coating material). Both fractions are sieved 74.1, 74.2. This results in the development of the recyclable aluminium and copper foils in container 88.3, a separator fraction in container 88.1, and pure coating material in containers 88.4 and 88.2; due to its high de-30 gree of purity, this material can be processed further in subsequent metallurgic process steps. This application is a divisional application of Australian patent application num- 2024278642   19 Dec 2024 ber 2022275436 originally filed on 23 November 2022, which in turn is a divsion-al of Australian patent application number 2017347388, originally filed on 18 April 2019, the contents of each are hereby incorporated by express cross- reference in their entirety. 5 2024278642   19 Dec 2024 Reference list 10 battery 58 second conveyor 12 discharge unit 60 breakdown comminutor 14 dismantling station 62 separator 16 cell 64 transport container 18 comminution unit draining device 19 liquid nitrogen source 66 breakdown material 68 third conveyor 20 shielding gas 22 shielding gas cylinder 70 fourth conveyor 24 comminuted material 72 sifted material 26 drying device 74 classification device 27 airlock in front of comminutor 76 active material fraction 28 airlock 78 transport container 29 vacuum installation 80 carrier fraction 30 82 fifth conveyor vacuum pump 31 gas 84 filling unit 32 gas purification device 86 container 34 condenser 88 additional filling unit 36 activated charcoal filter 90 particle removal device 38 condensate container 92 container 40 control valve 94 oxidation device 41 agitator 96 exit airlock 42 inactive comminuted material 98 silo 44 filling device 100 heavy material separator 46 transport container 102 comminutor 48 flushing line 108 light material 50 pressurised gas cylinder 110 heavy material 52 battery processing installation p force 54 standard container 56 first conveyor

Claims

2024278642  08 Jan 2025Patent claims1. A method for treating comminuted used lithium batteries that include a cathode, anode, separator, and electrolyte, wherein the electrolyte comprises a fluorine salt and a solvent, the solvent including an organic carbonate, comprising an organic carbonate, the method containing the steps: drying the comminuted material by removal of organic carbonate from the electrolyte by vaporizing the organic carbonate at a pressuretemperature above a boiling point of the organic carbonate, the pressure being not more than 300 hPa and the temperature being below a decomposition temperature of the fluorine salt such that an inactivated comminuted material is obtained,wherein the drying process is carried out in batch mode and wherein the drying is only stopped, when organic carbonates of the electrolyte that have a low boiling point have been removed so that no flammable or explosive gas phase can form above the battery fragments and the comminuted material is largely inert.

2. The method according to claim 1, whereinthe comminuted material is transported after drying by means of a discontinuously feeding conveyor to a separating device.

3. The method according to claim 1, whereinthe temperature is chosen so that the formation of relevant quantities of fluorophosphates, hydrogen fluoride, carbon monoxide, polyfluorinated dibenzodioxins and dibenzofurans, nitrogen oxides, carbonyl fluoride and / or hydrogen cyanide can be ruled out.2024278642  08 Jan 20254. The method according to claim 1, further including the step: condensing the gases that were created during the drying process, in particular at an ambient pressure and / or a temperature above -10°C and / or below 50°C.

5. The method according to claim 1, wherein- a minimum pressure during the drying process is at most 150 hPa.

6. The method according to claim 1, wherein- the comminuted material is moved in the drying device by means of an agitator, and- the agitator is used to supply at least 35% of an evaporation heat required for the drying of the comminuted material.

7. The method according to claim 1, wherein the comminution and drying processes are conducted at least in part within one container only.

8. The method according to claim 1, whereinthe comminuted material is dried until at least 90 percent by weight of dimethyl carbonate and / or ethyl methyl carbonate is removed.

9. A battery processing installation for the treatment of batteries, in particular lithium batteries, with:(a) a comminution unit for comminuting the batteries such that comminuted material is obtained,the comminution unit containing comminuted used lithium batteries that include a cathode, anode, separator, and electrolyte, wherein the electrolyte comprises a fluorine salt and a solvent, the solvent including an organic carbonate, comprising an organic carbonate,(b) a drying device for drying the comminuted material,2024278642  08 Jan 2025(c) a vacuum installation that is connected to the drying device for the purpose of generating a pressure of at most 300 hPa in the drying device, and(d) wherein the drying device is configured to dry at a maximum temperature below a decomposition temperature of the fluorine salt and(e) wherein the drying device is set up to stop drying, when organic carbonates of the electrolyte that have a low boiling point have been removed so that no flammable or explosive gas phase can form above the battery fragments and the comminuted material is largely inert and can be safely transported.

10. The battery processing installation according to claim 8, wherein the comminution unit is arranged in the drying device.

11. The battery processing installation according to claim8,whereina condenser for condensing gaseous electrolytes that have been sucked out of the dryer,wherein a particle separator is arranged between the drying device and the condensor and / or the at least one pump in the direction of material flow.

12. The battery processing installation according to claim 8, comprisinga gas-tight and or dust-tight conveyor which connects the comminution device and the drying device.

13. The battery processing installation according to claim 8, wherein- an airlock that is arranged in front of the comminution unit for supplying the batteries, and / or- a particle separator, which is arranged between the drying device and the condenser in the direction of material flow.

14. The battery processing installation according to one of the claims 8 to 13, wherein the drying devicecomprises at least one dry-running vacuum pump,2024278642  08 Jan 2025especially at least two vacuum pumps whose volume flows at 400 hPa and maximum achievable minimum pressures differ.

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