Nonflammable recycling apparatus and methods of use

Abstract

Set forth herein are apparatus for recycling a variety of devices, such as, but not limited to, electrochemical devices that are flammable, reactive, that contain flammable materials, or that become flammable or reactive during recycling processing. Certain apparatus include nonflammable or nonreactive parts, such as, but not limited to, nonflammable conveying mechanisms and / or nonreactive conveying mechanisms. Also set forth herein are processes for using these apparatus. The processes include means for reducing or eliminating thermite and / or thermite-like reactions during the processing of electrochemical devices. In certain embodiments, the electrochemical devices include, but are not limited to, batteries (e.g., lithium-ion batteries or lithium-metal batteries), and battery components such as cathodes, electrolytes, anodes, and current collectors.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of, U.S. Provisional Patent Application No. 63 / 551,885, filed February 9, 2024, the entire contents of which are herein incorporated by reference in its entirety for all purposes. FIELD

[0002] The present disclosure concerns the recycling of batteries, battery components, devices that include batteries, and other related electronic devices and materials. BACKGROUND OF THE INVENTION

[0003] Batteries, and in particular rechargeable batteries, are increasingly being used in transportation and electrical device applications. Lithium ion batteries, for example, are a type of rechargeable batteries that are widely being adopted in a variety of automotive applications, from personal vehicles to autonomous fleets of robots, drones, and transportation devices.

[0004] The abundance of rechargeable batteries creates a waste problem once these batteries expend their useful lifetime. Recycling of waste batteries is one solution to this waste problem. However, recycling of batteries involves a variety of challenges.

[0005] One challenge is the potential for exothermic reactions to occur during the disassembling, milling, and separating of batteries and their components. For example, batteries include a variety of metals, such as, but not limited to, lithium, aluminum, iron, nickel, manganese, cobalt, zinc, and others. Batteries, and the devices that contain batteries, are ground to their constituent components, or otherwise downsized, so that they can then be further processed. During processing, valuable, higher purity extracts such as graphite or pure nickel and copper, can be refined. But during the grinding, shredding, and dissembling processes, the resulting downsized battery scrap may undergo exothermic reactions. For example, lithium metal is flammable in air. Finely milled aluminum may react in a thermite reaction with iron oxide or other metal oxides such as nickel oxide. Given the metals inside batteries, highly exothermic reactions are possible during battery recycling.

[0006] What is needed are methods and apparatus for detecting, preventing, and mitigating thermal events during battery recycling. Set forth herein are solutions to the aforementioned challenge as well as others in the relevant field to which the instant disclosure pertains. SUMMARY OF THE INVENTION

[0007] In one embodiment, set forth herein is an apparatus that includes a shredding device coupled to a nonreactive conveyance member.

[0008] In a second embodiment, set forth herein is a process that includes conveying a flammable material through an apparatus having a shredder disclosed herein; detecting a thermal event in or downstream of the shredder; and stopping or reversing the conveying.

[0009] In a third embodiment, set forth herein is a process that includes conveying battery scrap through an apparatus disclosed herein, and generating active material powder.

[0010] In a fourth embodiment, set forth herein is a process that includes conveying a reactive material through an apparatus that includes a shredding device coupled to a nonreactive conveyance member; detecting a thermal event in or downstream of the shredding device; and stopping or reversing the conveying. BRIEF DESCRIPTION OF DRAWINGS

[0011] FIG. 1 shows an embodiment of a recycling apparatus that includes nonreactive conveyance structures.

[0012] FIG. 2 shows another embodiment of a recycling apparatus that includes nonreactive conveyance structures.

[0013] FIG. 3 shows an embodiment of a shredder with conveyance structures upstream and downstream of the shredder.

[0014] FIG. 4 shows an embodiment of a system and process for conveying battery scrap through a recycling apparatus disclosed here.

[0015] FIG. 5 shows an embodiment of a system for a shredder hopper and conveyor with thermal and flame detectors.

[0016] FIG. 6 shows temperature as a function of time for the shredder output chute in Example 2.

[0017] FIG. 7 shows optical and thermal images of the shredder output chute in Example 2. FIG. 7 shows a heat map on the bottom in which blue and black colors (darker) illustrate lower temperatures than the white, yellow, orange, and red colors (lighter) which illustrate higher temperatures. The crosshair in the lower right shows some of the highest temperatures illustrated in FIG. 7.

[0018] FIG. 8 shows optical and thermal images of the shredder output chute in Example 2. FIG. 8 shows a heat map on the bottom in which blue and black colors (darker) illustrate lower temperatures than the white, yellow, orange, and red colors (lighter) which illustrate higher temperatures. The crosshair in the lower right shows some of the highest temperatures illustrated in FIG. 8. DETAILED DESCRIPTION OF THE INVENTION

[0019] Disclosed herein are apparatus and processes for recycling batteries, battery components, devices that include batteries, and other related electronic devices and materials, while detecting, mitigating, preventing, or hindering thermal events in or on the processing line. DEFINITIONS

[0020] As used herein, the phrase “battery scrap,” refers to used batteries, such as but not limited to lithium-ion batteries, devices that include used batteries, as well as the components of used batteries. Battery scrap also includes battery production scrap, which is scrap material used to make a battery but before a battery is actually made. For example, waste material during the making of a battery would be a type of battery production scrap. A used battery includes, but is not limited to, a battery that has been charged, discharged, or both, at least once. A used battery includes, but is not limited to, a battery that has been sold. In certain embodiments, battery scrap includes just the cathode portion of a battery. In other embodiments, the cathode and anode of a battery are included in the battery scrap. In some of these embodiments, the battery scrap is calcined to deactivate the battery when the battery includes both cathode and anode materials.

[0021] As used herein, the phrase “lithium ion battery scrap,” refers to battery scrap as defined above that is, or originates, from a lithium ion battery.

[0022] As used herein, the phrase “active material powder,” refers to fractions from shredded or comminuted electrochemical cells. The active material powder may include a powder comprising electrode materials including electrode active materials, polymeric binder, and aluminum, nickel, and copper current collector material. The chemical composition of active material powder depends upon the chemistry of the scrap electrochemical cells. Active material powder may include nickel and nickel compounds, cobalt and cobalt compounds, manganese and manganese compounds, aluminum and aluminum compounds, copper and copper compounds, graphite, lithium metal and lithium compounds, polymers, binders, oxides thereof, and the calcined metal components thereof, as well as combinations thereof.

[0023] As used herein, “downstream,” refers to process steps and apparatus components that are positioned after another process step or apparatus part / component, in which “after” refers to the direction of travel of materials in a process line during a recycling process. The direction of travel does not include the direction of travel when the apparatus runs in reverse following a thermal event.

[0024] As used herein, “upstream,” refers to process and apparatus components that are positioned before another process step or part / component, in which “before” refers to the direction of travel of materials in a process line during a recycling process. The direction of travel does not include the direction of travel when the apparatus runs in reverse following a thermal event.

[0025] As used herein, the phrase “cathode material,” refers to the positive electrode component of a battery and includes cathode active materials, binders, organic solvents, lithium salts, and lithium-ion conducting materials, as well as combinations thereof. Cathode materials may include, but are not limited to, lithium iron phosphate active materials, nickel manganese cobalt oxide active materials, manganese oxides, nickel oxides, cobalt oxides, nickel cobalt aluminum oxide active materials and combinations thereof.

[0026] As used herein, the phrase “anode material,” refers to the negative electrode component of a battery and includes anode active materials, graphite, and combinations thereof. Anode material may also include current collector material, such as copper, aluminum, and nickel.

[0027] As used herein, the phrase “conveyance member,” refers to a part of a processing line that moves material from one point of the line to another point of the line.

[0028] As used herein, “flammable,” refers to the property of a material to combust and react with oxygen when exposed to heat or exothermic reactions from reactive materials described herein.

[0029] As used herein, the phrase “reactive material,” refers to a material or collection of materials that react exothermically under solid-state conditions. An example reactive material is milled aluminum. Milled aluminum has a high surface area. As such, milled aluminum reacts with iron oxide, i.e., rust or Fe20s, in a thermite reaction. A product of this thermite reaction is iron (Fe) that is molten on account of the exothermic release of energy that accompanies this reaction. A reactive material may be an aluminothermic material. An aluminothermic material is a material that react with aluminum metal and / or metal oxides such as iron oxide, nickel oxide, and other oxides.

[0030] As used herein, the phrase “magnetic separation device,” refers to a device capable of separating magnetic from nonmagnetic material. For example, a table that has a magnet on, or in, it will attract milled iron in a collection of milled iron, milled aluminum, and milled copper. Of these three metals, only iron might be magnetic; aluminum and copper are not magnetic. In a processing line, a collection of materials may include different types of metals. A magnet separation device would be used to separate or isolate the magnetic components from the non-magnetic components. As the processing line progresses, iron would accumulate on the magnet of the magnetic separation device and nonmagnetic material would continue to move past the magnetic separation device. Commercially available magnetic separation devices include, but are not limited to, a magnetic drum separator, a vibratory feed magnetic plate separator, a magnetic plate separator (i.e., in a transition chute), and a cross-belt magnetic separator.

[0031] As used herein, “nonreactive,” refers to the property of a material to not react with battery scrap material, or the shredded, disassembled, milled, or downsized components thereof.

[0032] As used herein, “nonflammable,” refers to the property of a material to not combust and react with oxygen when exposed to heat or exothermic reactions from reactive materials described herein.

[0033] As used herein, the phrase “nonreactive conveyance member,” refers to a part of a processing line that moves material from one point of the line to another point of the line and that is nonreactive, as defined herein. For example, a conveyance belt that moves material through a processing line is a conveyance member. A conveyance belt that is not reactive, such as a belt made exclusively of aluminum, is a non-limiting example of a nonreactive conveyance member. A conveyance belt that is not reactive, such as a belt made exclusively of steel, is a non-limiting example of a nonreactive conveyance member.

[0034] As used herein, the phrase “nonreactive material,” refers to a material that is not a reactive material, as defined above. A nonreactive material may include a nonreactive metal such as aluminum sheet metal. Aluminum sheet metal would not react with milled aluminum to produce an exothermic reaction. A nonreactive material may include a composite that includes certain nonflammable refractory components in combination with certain nonreactive metals.

[0035] As used herein, the phrase “refractory,” refers to the property of a non-metallic material to be resistant to heat and chemical degradation. Refractory materials also tend to maintain strength and rigidity at elevated temperatures. Certain ceramics are considered refractory materials but metals are not considered refractory materials. For example, certain ceramics may be heated to high temperatures in air without undergoing any chemical or physical changes. Metals, by contrast, tend to liquify if not also oxidize when heated to high temperatures in air. Metals conduct heat well whereas ceramics tend not to conduct heat well. Because of their resistance to heat, refractory materials are often used in certain kilns, furnaces, reactors, and vessels that transport molten metal.

[0036] As used herein, the phrase “thermal event,” refers to an exothermic reaction that is detectable by devices such as an infrared-sending camera, a heat detector, a spark detector, a temperature sensor, a thermocouple, a thermometer, or combinations thereof. Some example devices include, but are not limited to, IR cameras by Teledyne FLIR. Some example devices include, but are not limited to, flame detectors made by Spectrex and Det-Tronics. Some example devices include, but are not limited to, thermocouples from McMaster Carr, Omega, and other suppliers.

[0037] As used herein, the phrase “separated aluminum,” refers to aluminum that has a higher purity of aluminum than in the battery scrap from which it was recycled and processed.

[0038] As used herein, the phrase “separated copper,” refers to copper that has a higher purity of copper than in the battery scrap from which it was recycled and processed. APPARATUS

[0039] In an embodiment, set forth herein is an apparatus that includes a shredding device coupled to a nonreactive conveyance member. During certain recycling processes, metallic components of the battery, such as aluminum, are ground up, milled, or otherwise downsized. This process introduces energy into these components. For example, milled aluminum has the potential to react with iron oxide. With sufficient introduction of energy, these downsized metallic components may initiate exothermic reactions such as an aluminothermic reactions between aluminum and nickel oxide. Thermite reactions in which iron oxide (F62()3) and aluminum react to form iron (Fe) and aluminum oxide (AI2O3) may also occur. Other exothermic reactions are possible. Exothermic reactions cause propagating exothermic reactions such as fires that burn organic components of an apparatus line, such as rubber conveyor belts. To avoid these propagating reactions, the apparatus disclosed herein do not include parts or components that can react exothermically or burn when exposed to heat. Reacting exothermically includes combusting on contact with reactive materials, such as those that may initiate a thermite reaction or fire. In some embodiments, to avoid these propagating reactions, the apparatus disclosed herein does not include parts that can react exothermically, or combust, at the points in a process line where a thermite reaction, a thermite-like reaction, or a fire may occur or is likely to occur during battery recycling. For example, the conveyance members adjacent to shredders are made of nonreactive or nonflammable materials so that fires do not propagate if exothermic reactions are initiated in the shredders.

[0040] One embodiment of an apparatus disclosed herein is shown in FIG. 1. FIG. 1 shows a process line that starts with a Gaylord Tipper. The Gaylord Tipper is covered by a Hygiene Shroud. A vibratory feeder is mechanically coupled to the Gaylord Tipper such that material in the Gaylord Tipper can be moved from the Gaylord Tipper to the vibratory feeder. The apparatus shown in FIG. 1 has the vibratory feeder coupled at a right angle to a Shredder Metal Belt Conveyor. The apparatus may be configured in a variety of ways. For example, the vibratory feeder and the Shredder Metal Belt Conveyor may be positioned at different angles with respect to each other. Other arrangements are possible and contemplated herein. The apparatus, in some other embodiments, may have the components shown in a straight line or a line with a variety of curves and angles in between each component. The Shredder Metal Belt Conveyor is angled upwards so as to move material thereupon up and into the Shredder. The Shredder includes an internal space for material to fall towards the ground and thereby interact with at least one or more internal shredding mechanisms. As material exits the Shredder, the material is conveyed to an Impact Mill Metal Belt Conveyor. The Impact Mill Metal Belt Conveyor is angled upwards to as to move material thereupon up and into the Impact Mill. In certain embodiments, at least the Shredder Metal Belt Conveyor and the Impact Mill Metal Belt Conveyor are made of a non-reactive material or materials, nonflammable material or materials, or both nonreactive and nonflammable material or materials. In other embodiments, other components in addition to the Shredder Metal Belt Conveyor and the Impact Mill Metal Belt Conveyor are made of a non-reactive, nonflammable, or both, material or materials. This is to prevent the Shredder Metal Belt Conveyor and the Impact Mill Metal Belt Conveyor from burning or combusting if the shredder creates reactive or flammable materials, such as those that initiate thermite or thermite-like reactions.

[0041] In some embodiments, including any of the foregoing, the nonreactive conveyance member is a nonflammable conveyance member.

[0042] In some embodiments, including any of the foregoing, the conveyance member is not under immersion conditions or submerged in water. This means that, in certain embodiments, the conveyance member is exposed to air. In these certain embodiments, the conveyance member is not immersed in an inert gas, such as 100% nitrogen or argon. In these certain embodiments, the conveyance member is also not operated under water or under a water spray.

[0043] In some embodiments, including any of the foregoing, the apparatus is exposed to the atmosphere.

[0044] In some embodiments, including any of the foregoing, the shredding device is a shredder or a comminutor. In some of these embodiments, the shredding device is a shredder. In some of these embodiments, the shredding device is a comminutor. In certain of these embodiments, the shredding device is a shredder selected from a single-shaft shredder. In some other of these embodiments, the shredding device is a shredder selected from a dual-shaft shredder. In yet other embodiments, the shredding device is a shredder selected from a four-shaft shredder.

[0045] In some embodiments, including any of the foregoing, the shredding device is a shredder within, or coupled to, a sealed fines collection bin. Fines are the downsized, shredded, or milled products of battery scrap. Fines include downsized, shredded, or milled metals.

[0046] In some embodiments, including any of the foregoing, the nonreactive conveyance member comprises a nonflammable conveyance belt.

[0047] In some embodiments, including any of the foregoing, the nonreactive conveyance member comprises a nonreactive conveyance belt.

[0048] In some embodiments, including any of the foregoing, the nonflammable conveyance member comprises a nonflammable conveyance belt. In certain embodiments, the cleats on the conveyor are made of any sort of metal or alloy thereof. In certain of these embodiments, the cleats on the conveyor are made of aluminum or an alloy thereof. In certain of these embodiments, the cleats on the conveyor are made of steel. In certain embodiments, the cleats are welded on to the conveyor. In certain embodiments, the cleats are bolted on to the conveyor to create a raised barrier between sections of the belt.

[0049] In some embodiments, including any of the foregoing, the conveyance belt comprises nonflammable cleats.

[0050] In some embodiments, including any of the foregoing, the conveyance belt comprises nonreactive cleats.

[0051] In some embodiments, including any of the foregoing, the nonreactive conveyance member is made of, or coated with, a nonflammable material selected from the group consisting of a nonflammable metal, a nonflammable alloy, a nonflammable composite, a high temperature resistant metal, a high temperature resistant alloy, a refractory material, and combinations thereof.

[0052] In some embodiments, including any of the foregoing, the nonreactive conveyance is made of aluminum, iron, steel, or a combination thereof. In certain embodiments, including any of the foregoing, the nonreactive conveyance is made of aluminum. In certain other embodiments, including any of the foregoing, the nonreactive conveyance is made of iron. In certain other embodiments, including any of the foregoing, the nonreactive conveyance is made of steel. In yet other embodiments, including any of the foregoing, the nonreactive conveyance is made of a combination of aluminum, iron, or steel.

[0053] In some embodiments, including any of the foregoing, the nonreactive conveyance member is selected from at least one or more members from the group consisting of a conveyor with a nonflammable belt, a drag conveyor, a vibratory feeder with a nonflammable trough, an auger, and combinations thereof. Depending on the apparatus, the nonreactive conveyance member is a conveyor with a nonflammable belt. In certain other embodiments, the nonreactive conveyance member is a drag conveyor. In certain other embodiments, the nonreactive conveyance member is a vibratory feeder. In certain other embodiments, the nonreactive conveyance member is a nonflammable trough. In certain other embodiments, the nonreactive conveyance member is an auger.

[0054] In some embodiments, any components directly exposed to reactive material and any nearby components are nonflammable, nonreactive, or both, because of the potential high temperatures during a thermite event.

[0055] An example Fire Mitigation component of an apparatus is shown in FIG. 2. FIG. 2 is the same apparatus as in FIG. 1 but FIG. 2 also shows the locations of dust collection points.

[0056] The apparatus shown in FIG. 2 includes means for reducing the likelihood of a fire or thermal event. These means include an infeed controller that can minimize the amount of material in the shredder hopper. These means also include devices (such as a cameras) for visually inspecting for foreign objects. These means (such as a magnetic separator) also include devices for magnetically separating foreign objections.

[0057] The apparatus shown in FIG. 2 includes means for containing any thermal events that occur. The apparatus shown eliminates rubber belt conveyors and has an all meal design for the conveyors and shredder hopper. The apparatus may include sacrificial or replaceable metal conveyor pans.

[0058] The apparatus shown in FIG. 2 includes means for detecting thermal events and means for cooling the same. These means include IR cameras, spark detectors, temperature sensors, and combinations thereof.

[0059] In some embodiments, including any of the foregoing, the nonflammable trough is made of Cu, a refractory material, or a combination thereof.

[0060] In some other embodiments, including any of the foregoing, the nonflammable trough is made of aluminum, iron, steel, or a combination thereof.

[0061] In some embodiments, including any of the foregoing, at least one nonreactive conveyance member is coupled to and downstream of the shredding device.

[0062] In some embodiments, including any of the foregoing, the shredding device is coupled to a milling device by a metal belt conveyor.

[0063] In some embodiments, including any of the foregoing, the milling device is an impact mill.

[0064] In some embodiments, including any of the foregoing, the nonflammable conveyance member is coupled to a vibratory feeder.

[0065] In some embodiments, including any of the foregoing, the vibratory feeder is coupled to a Gaylord Tipper.

[0066] In some embodiments, including any of the foregoing, the apparatus further includes at least one device for detecting a thermal event.

[0067] In some embodiments, including any of the foregoing, the at least one device for detecting a thermal event is selected from the group consisting of an infraredsending camera, linear heat detector running the length of the conveyor, a spark detector, a temperature sensor, a thermocouple, a thermometer, and combinations thereof.

[0068] In some embodiments, including any of the foregoing, the at least one device for detecting a thermal event is an ultraviolet-infrared (UV-IR) camera.

[0069] In some embodiments, including any of the foregoing, the at least one device for detecting a thermal event is flame detector.

[0070] In some embodiments, including any of the foregoing, one of the at least one device for detecting a thermal event is positioned inside and on a vertical side of the shredding device, inside and at the top of the shredding device, inside and at the base of the shredding device, at the shredder infeed, at the shredder outfeed chute and conveyor, at the outfeed conveyor coupled to the impact mill, or a combination thereof.

[0071] In some embodiments, including any of the foregoing, one of the at least one device for detecting a thermal event is positioned at the base of the nonreactive conveyance member.

[0072] In some embodiments, including any of the foregoing, the apparatus is not enclosed in an atmosphere comprising an inert gas. In certain embodiments, the inert gas is nitrogen (N2) gas with less than 18% oxygen (O2). In certain embodiments, the inert gas is argon (Ar). In certain embodiments, the inert gas is a combination thereof N2, O2, and Ar.

[0073] In some embodiments, including any of the foregoing, the apparatus further includes at least one or more means for detecting dust, reducing dust, collecting dust, detecting aluminum, removing aluminum, separating aluminum, detecting copper, removing copper, separating copper, or a combination thereof. These means may include, but are not limited to, vacuums, blowers, collection bins, filters, and combinations thereof.

[0074] In some embodiments, including any of the foregoing, the apparatus further includes a tipper, a vibratory feeder, or a combination thereof.

[0075] In some embodiments, including any of the foregoing, the vibratory feeder further comprises vibratory feed speed controls.

[0076] In some embodiments, including any of the foregoing, the apparatus further includes infeed controls for controlling the amount of material in the shredding device.

[0077] In some embodiments, including any of the foregoing, the apparatus further includes a sorting conveyor coupled a shredder metal belt conveyor, wherein the shredder metal belt conveyor is coupled upstream of the shredding device.

[0078] In some embodiments, including any of the foregoing, the shredder metal belt conveyor is inclined and the shredding device is positioned higher than the sorting conveyor.

[0079] In some embodiments, including any of the foregoing, the apparatus further includes at least one magnetic separation device.

[0080] In some embodiments, including any of the foregoing, at least one magnetic separation device is positioned immediately before the milling device.

[0081] In some embodiments, including any of the foregoing, at least one magnetic separation device is positioned immediately before the shredder metal belt conveyor.

[0082] In some embodiments, including any of the foregoing, the apparatus is configured for an infeed capacity of at least 2 metric tons per hours. This means that the volume of material that can be processed is at least 2 metric tons per hour of operation of the apparatus. The volume, in certain examples, is less than 1,000 metric tons; or less than 100 metric tons. PROCESSES

[0083] In some embodiments, set forth herein is a process that includes conveying a reactive material through an apparatus disclosed herein; detecting a thermal event in or downstream of the shredder; and stopping or reversing the conveying.

[0084] In some embodiments, set forth herein is a process that includes conveying a reactive material through an apparatus disclosed herein; detecting a thermal event in or downstream of the shredder; and reversing the conveying so as to dump or remove certain hot material off the tail of the conveyor. In certain embodiments, the hot material may be deposited into a contained area. In certain embodiments, the hot material may be deposited in a box of sand.

[0085] In some embodiments, set forth herein is a process that includes conveying battery scrap through an apparatus disclosed herein; and generating active material powder. Active material powder may, in some embodiments, be made by shredding alone. Active material powder may, in some other embodiments, be made by shredding and calcining.

[0086] In some embodiments, set forth herein is a process that includes conveying a reactive material through an apparatus comprising a shredding device coupled to a nonreactive conveyance member; detecting a thermal event in or downstream of the shredding device; and stopping or reversing the conveying.

[0087] In some embodiments, set forth herein is a process that includes conveying a reactive material through an apparatus comprising a shredding device coupled to a nonreactive conveyance member; detecting a thermal event in or downstream of the shredding device; and stopping the conveying. CERTAIN PROCESS EMBODIMENTS

[0088] The below process steps may be implemented in the system shown in FIG. 4. For example, FIG. 4 shows a box of battery scrap (401), the contents of which are conveyed to a box tipper (402), then to a shredder (403), and then to a feed conveyor (404). FIG. 4 shows that the feed conveyor (404) sends some material to an impact mill (406) and then separates (407) copper (Cu) and aluminum (Al). FIG. 4 shows that the feed conveyor sends some material to a magnetic separator (405).

[0089] In some embodiments, lithium ion batteries (LIB) scrap are used as a feed material and thereafter produce active material powder. LIB scrap will primarily include cathode scrap materials in various form factors, but other LIB scrap is contemplated within the scope of the instant disclosure. In some embodiments, LIB scrap boxes is delivered to a box tipper by forklift. From the tipper, scrap boxes are then emptied into a vibratory feeder. LIB scrap boxes will, in some examples, be tipped into a funnel over the vibratory feeder. From the feeder, the scrap material will, in some embodiments, be transported to the Shredder Infeed Conveyor, a metal belt conveyor which feeds into the shredder. This metal belt conveyor is an example of a nonreactive conveyance member. The all metal vibratory feeder is an example of a nonreactive conveyance member. The all metal apron feeder is an example of a nonreactive conveyance member. The all metal drag conveyor is an example of a nonreactive conveyance member.

[0090] Shredded material will, in some embodiments, be conveyed through another metal belt conveyor, an impact mill feed conveyor, and / or to an impact mill for further size reduction. Products of the mill are, in some embodiments, pneumatically transported to a cyclone stage. Underflow from the cyclone reports to a screener stage, while the overflow is transported by a blower stage and a dust collector.

[0091] Oversize particles from the upper sieve of screener stage are, in some embodiments, sent to an oversize bailing station. Oversize particles from the lower sieve of screener stage are fed to a delamination mill whose discharge is pneumatically transported to another cyclone stage. The undersize particles from the lower sieve of screener stage are transported by a screener screw conveyor and powder silo screw conveyor and then to a powder storage.

[0092] In some embodiments, an air table is used to separate aluminum and copper foils, in which the heavy materials route to a copper bagging station while the light materials route to an aluminum bagging station. Undersize material from a screener stage is transported by the screener screw conveyor and powder silo screw conveyor to the powder storage silo where, in some embodiments, active material powder accumulates.

[0093] In some embodiments, a powder storage silo feeds active material powder into a powder feeder, which is a loss-in-weight type system. The feeder, in some embodiments, drops powder onto a slurry screw conveyor, which leads to an active material powder slurry tank.

[0094] In some embodiments, at least one or more dust collectors discharge through airlocks to a dust collector screw conveyor, which feeds into a powder silo screw conveyor.

[0095] In some embodiments, dust collection pickups are placed in the following areas: Gaylord unloading shroud; Vibratory Feeder; Infeed Conveyor; Shredder enclosure; Shredded material Feed Conveyor; Magnetic separator box; Screener Stage vibratory screens; Air Table; Oversize plastic bagging station; Aluminum loadout bagging station; Copper loadout bagging station; Active material powder silo - bin vent filter; Powder loadout bagging station; Active material powder slurry tank; and Bag Unloader tie-untie box.

[0096] An exemplary apparatus is shown in FIG. 3. FIG. 3 shows a nonreactive conveyance member made out of metal that transports reactive material such as lithium ion battery scrap up and into a shredder that is enclosed. A device for sensing a thermal event, such as an infrared-sensing camera, a linear heat detector, a spark detector, a temperature sensor, a thermocouple, a thermometer, or a combination thereof, may be mounted anywhere practical above the shredder such that is provides an adequate field of view of the shredding process.

[0097] For example, see FIG. 5, which shows a series of detection devices such as a FLIR process camera, Det-Tronics triple IR detector, and a linear heat detector. FIG. 5 shows a FLIR infrared camera at the shredder infeed. FIG. 5 shows a linear heat detector along the conveyor to the impact mill. FIG. 5 shows two FLIR and triple IR (infrared camera) detectors and flame detectors at the shredder outfeed chute and conveyor. FIG. 5 shows two FLIR and triple IR detectors and flame detectors at the outfeed conveyor to the impact mill. The apparatus in FIG. 5 may also include a fire alarm tie-in. The tie-in may include the linear heat detector along both conveyors that activate when a threshold temperature is sensed. Below the shredder is another nonreactive conveyance member that receives the shredded material and conveys it upwards to an impact mill.

[0098] In some embodiments, material from tipper box dropped on to the vibratory feeder which will spread the material out and aid in metering it into downstream equipment at an even feed rate. There is access for visibility into the contents of gaylords and foreign object removal, if necessary. Material on feeder gets transferred into the infeed conveyor. The Vibratory Feeder is equipped with two motors, which are controlled by a single variable frequency device (VFD).

[0099] In some embodiments, there is a normal ( / . c., optical, video) camera watching the vibratory feeder.

[0100] In some embodiments, material from Vibratory Feeder is transferred onto a metal belt conveyor which will transfer material to the shredder. This conveyor provides access for foreign objects to be identified and removed, if necessary.

[0101] In some embodiments, an infeed conveyor is equipped with VFD to control the speed of the motor.

[0102] In some embodiments, pull cords will be acting as E-stop, which run along the conveyor length.

[0103] In some embodiments, linear heat detectors run along the length of the conveyor.

[0104] In some embodiments, zero-speed sensor switch are used to detect when the motor is running, and the conveyor belt stops.

[0105] In some embodiments, one photo-eye level sensor is equipped for high level detection on the Shredder hopper and a paddle switch at the discharge chute to monitor the level of process material.

[0106] In some embodiments, FLIR CAMERAS are used. In some embodiments, these cameras are used as process cameras and as well as for temperature profile monitoring.

[0107] In some embodiments, IR CAMERAS are used for flame detection and are a primary source of fire detection within the process.

[0108] In some embodiments, the shredder can detect jamming. In a jam, in some embodiments, it will reverse the direction of the cutting blades and restart normal operation. In some embodiments, it will complete this cycle up to 3 times to unjam the machine. If after 3 cycles the shredder remains jammed, the apparatus will sound an alarm and shutdown. In some embodiments, manual unjamming is required after the shutdown this point.

[0109] In some embodiments, from the feed conveyor, shredded material is fed to an impact mill for further size reduction.

[0110] In some embodiments, the pneumatic conveyance system is operating in service before an impact mill starts. In some embodiments, water sprays into an impact mill, as needed, to control chamber temperature. In some embodiments, water sprays are initiated once high temperature limit (UL) are reached and subsequently deactivated when low temperature limit (LL) are achieved. In some embodiments, the impact mill will shut down in a high-high temperature situation.

[0111] In some embodiments, the impact mill chamber and spindle bearings are equipped with temperature indicators to monitor operating conditions.

[0112] In some embodiments, the undersized material of a first screen from a screener stage is fed to a delamination mill dosing hopper that is equipped with a rotary airlock. From the rotary airlock, milled scrap material is fed to the delamination mill.

[0113] In some embodiments, the vibratory screener receives feed material from the rotary airlock. In some embodiments, oversize material (typically plastics) from the upper deck (+3 Mesh) is sent to the oversize bagging station. In some embodiments, oversize material of the second deck (+60 Mesh) is fed to the delamination mill dosing chute. In some embodiments, undersize material of the second deck (-60 Mesh) is fed to the Screener Screw Conveyor.

[0114] In some embodiments, dust collection is attached to the top deck to pull a slight draft on the machine to keep material from seeping out over time.

[0115] In some embodiments, a screen stage receives feed from delamination mill and separates aluminum and copper from active material powder. In some embodiments, this screener will automatically start once the delamination mill system is online. In some embodiments, there are blockage detection sensors at the bottom of apparatus transitions. These sensors can then send a signal that stops the delamination system if the sensors detect any blockage overfilling the downstream equipment.

[0116] In some embodiments, separated aluminum and copper material from a screener are conveyed to an air table. In some embodiments, an air table then separates aluminum and copper. In some embodiments, the air table will automatically start once a screener stage is in service. In some examples, this produces separated aluminum, separated copper, or both.

[0117] In other embodiments, set forth herein is a non-transitory computer readable medium comprising program instructions for battery recycling that, when executed by an apparatus, cause an apparatus to perform at least a process disclosed herein. ACTIVE MATERIAL POWDER

[0118] Active material powder made by a process disclosed herein.

[0119] In some embodiments, the active material powder also includes separated aluminum, copper, or a combination thereof.

[0120] In some embodiments, the active material powder is produced along with separated aluminum, copper, or a combination thereof. EXAMPLES EXAMPLE 1 - RECYCLING BATTERIES

[0121] In this example, metric tons (mt) of battery scrap are processed. The apparatus used demonstrated a Gaylord Loading Rate (in minutes) as a function of Throughput [in metric tons per hour (h)] and Gaylord Weight as shown in Table 1 below. TABLE 1 Throughput (mt / h) 2000 3000 4000 5000 Gaylord weight (kg) 100 3.0 2.0 1.5 1.2 150 4.5 3.0 2.3 1.8 200 6.0 4.0 3.0 2.4 250 7.5 5.0 3.8 3.0

[0122] Lithium-ion battery cathode material was shredded, followed by dual granulation and screening to produce -60 mesh active material powder feed.

[0123] The following equipment were included in the apparatus: Bulk Bag Unloader; Powder Bag Unload Conveyor; Vibratory Feeder; Shredder Feed Conveyor; and an Impact Mill Feed Conveyor. EXAMPLE 2 - DETECTING A THERMAL EVENT

[0124] This Examiner shows a High Temperature event at the shredder discharge.

[0125] Lithium-ion battery cathode scrap was continuously milled. A thermal imager detected a rise in temperature in the material being shredded above 400 °C. Multiple temperature spikes about 100 °C were also observed before the spike above 400 °C was observed. See FIG. 6. An interlock was thereafter tripped, and the shredder was stopped. The thermal event did not propagate.

[0126] The three temperature plots in FIG. 6 show temperature at three locations of the process that were monitored with FLIR cameras. The three locations included the shredder hopper, the shredder discharge, and the shredder-impact mill conveyor discharge.

[0127] FIG. 7 and FIG. 8 show two subsequent time stamps. The upper image is the shredder hopper, and the lower image is the shredder discharge (in heat map view). FIG. 7 shows the initiation of the thermal event. FIG. 8 shows several seconds later where the peak temperatures occur in the shredder discharge.

[0128] A hot event was detected. The hot event may have damaged some links. But the thermal event was stabilized and cooled off without human intervention. No spreading or propagation of the thermal event occurred. There was no significant belt damage. See FIGs. 7 and 8.

[0129] The embodiments and examples described above are intended to be merely illustrative and non-limiting. Those skilled in the art will recognize or will be able to ascertain using no more than routine experimentation, numerous equivalents of specific compounds, materials and procedures. All such equivalents are considered to be within the scope and are encompassed by the appended claims.

[0130] All publications and patent, applications cited in this specification are herein incorporated by reference as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. While the claimed subject matter has been described in terms of various embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the subject matter limited solely by the scope of the following claims, including equivalents thereof.

Claims

1. An apparatus comprising a shredding device coupled to a nonreactive conveyance member.

2. The apparatus of claim 1, wherein the nonreactive conveyance member is a nonflammable conveyance member.

3. The apparatus of claim 1 or 2, wherein the conveyance member is not under immersion conditions or submerged in water.

4. The apparatus of any one of claims 1-3, wherein the apparatus is exposed to the atmosphere.

5. The apparatus of any one of claims 1-4, wherein the shredding device is a shredder or a comminutor.

6. The apparatus of any one of claims 1-5, wherein the shredding device is a shredder within, or coupled to, a sealed fines collection bin.

7. The apparatus of any one of claims 1-6, wherein the nonreactive conveyance member comprises, consists, or consists essentially of, a nonflammable conveyance belt.

8. The apparatus of claim 7, wherein the conveyance belt comprises nonflammable cleats.

9. The apparatus of any one of claims 1-8, wherein the nonreactive conveyance member is made of, or coated with, a nonreactive material selected from the group consisting of a nonreactive metal, a nonreactive alloy, a nonreactive composite, a high temperature resistant metal, a high temperature resistant alloy, a refractory material, and combinations thereof.

10. The apparatus of any one of claims 1-9, wherein the nonreactive conveyance member is made of, or coated with, a nonflammable material selected from the group consisting of a nonflammable metal, a nonflammable alloy, a nonflammable composite, a high temperature resistant metal, a high temperature resistant alloy, a refractory material, and combinations thereof.

11. The apparatus of any one of claims 1-10, wherein the nonreactive conveyance is made of aluminum, iron, steel, stainless steel, carbon steel, or a combination thereof.

12. The apparatus of any one of claims 1-11, wherein the nonreactive conveyance member is selected from at least one or more members from the group consisting of a conveyor with a nonflammable belt, a drag conveyor, a vibratory feeder with a nonflammable trough, an auger, and combinations thereof.

13. The apparatus of claim 12, wherein the nonflammable trough is made of Cu, a refractory material, or a combination thereof.

14. The apparatus of any one of claims 1-13, wherein at least one nonflammable conveyance member is coupled to and downstream of the shredding device.

15. The apparatus of any one of claims 1-14, wherein the shredding device is coupled to a milling device that is coupled to a metal belt conveyor.

16. The apparatus of claim 15, wherein the milling device is an impact mill.

17. The apparatus of any one of claims 1-16, wherein the nonreactive conveyance member is coupled to a vibratory feeder.

18. The apparatus of claim 17, wherein the vibratory feeder is coupled to a Gaylord Tipper.

19. The apparatus of any one of claims 1-18, further comprising at least one device for detecting a thermal event.

20. The apparatus of claim 19, wherein the at least one device for detecting a thermal event is selected from the group consisting of an infrared-sensing camera, linear heat detector running the length of the conveyor, a spark detector, a temperature sensor, a thermocouple, a thermometer, and combinations thereof.

21. The apparatus of any one of claims 19-20, wherein one of the at least one device for detecting a thermal event is positioned inside and on a vertical side of the shredding device, inside and at the top of the shredding device, inside and at the base of the shredding device, at the shredder infeed, at the shredder outfeed chute and conveyor, at the outfeed conveyor coupled to the impact mill, or a combination thereof.

22. The apparatus of any one of claims 19-21, wherein one of the at least one device for detecting a thermal event is positioned at the base of the nonreactive conveyance member.

23. The apparatus of any one of claims 1-22, wherein the apparatus is not enclosed in an atmosphere comprising an inert gas.

24. The apparatus of any one of claims 1-23, further comprising at least one or more means for detecting dust, reducing dust, collecting dust, detecting aluminum, removing aluminum, separating aluminum, detecting copper, removing copper, separating copper, or a combination thereof.

25. The apparatus of any one of claims 1-24, further comprising a tipper, a vibratory feeder, or a combination thereof.

26. The apparatus of claim 25, wherein the vibratory feeder further comprises vibratory feed speed controls.

27. The apparatus of any one of claims 1-26, further comprising infeed controls for controlling the amount of material in the shredding device.

28. The apparatus of any one of claims 1-27, further comprising a sorting conveyor coupled a shredder metal belt conveyor, wherein the shredder metal belt conveyor is coupled upstream of the shredding device.

29. The apparatus of claim 28, wherein the shredder metal belt conveyor is inclined and the shredding device is positioned higher than the sorting conveyor.

30. The apparatus of any one of claims 1-29, further comprising at least one magnetic separation device.

31. The apparatus of claim 30, wherein the at least one magnetic separation device is positioned immediately before the milling device.

32. The apparatus of any one of claims 1-31, further comprising at least one magnetic separation device positioned immediately before the shredder metal belt conveyor.

33. The apparatus of any one of claim 1-32, wherein the apparatus is configured for an infeed capacity of at least 2 metric tons per hours.

34. A process comprising:conveying a reactive material through an apparatus of any one of claims 1-33; detecting a thermal event in or downstream of the shredder;and stopping or reversing the conveying.

35. A process comprising:conveying battery scrap through an apparatus of any one of claims 1-33;and generating active material powder.

36. A process comprisingconveying a reactive material through an apparatus comprising a shredding device coupled to a nonreactive conveyance member;detecting a thermal event in or downstream of the shredding device; and stopping the conveying.

37. The process of any one of claims 34-34, wherein the reactive material is a flammable material.

38. The process of any one of claims 34-37, wherein the reactive material is lithium ion battery scrap, calcined lithium ion battery scrap, a component thereof, or a pack, module, or device containing a lithium ion battery.

39. The process of any one of claims 34-38, wherein the reactive material is cathode material or a processed derivative thereof.

40. The process of any one of claims 34-39, wherein the reactive material is conveyed on a metal belt conveyor into the shredding device.

41. The process of any one of claims 34-40, wherein the reactive material is conveyed from a feeder to a metal belt conveyor that feeds into the shredding device.

42. The process of any one of claims 34-41, wherein detecting a thermal event comprises detecting a rapid rise in temperature in the reactive material, detecting a temperature in the reactive material greater than 100 °C, detecting a temperature in the reactive material greater than 150 °C, or a combination thereof.

43. The process of claim 42, further comprising automatically shutting off the shredding device; reversing at least one conveyor; automatically shutting off dust collectors; pulling dust from the conveyor; automatically shutting off an impact mill; automatically shutting off an infeed system; automatically shutting off a blower that is transporting material into or through an impact mill downstream of the shredding device; automatically shutting off a blower that is transporting material into or through a delamination mill; automatically activating an interlock on a component in the process such that the process stops; using an alarm selected from a horn, a siren, a beacon, a light; or a combination thereof.

44. The process of any one of claims 34-43, wherein stopping the process comprises activating a pull cord.

45. The process of any one of claims 34-44, wherein stopping the process comprises automatically generating a control signal to stop the process.

46. The process of any one of claims 34-45, wherein stopping the process comprises shutting off all processes except dust collectors.

47. The process of any one of claims 37-46, wherein the process generates active material powder.

48. The process of any one of claims 37-47, wherein the process generates active material powder and separated aluminum, copper, or a combination thereof.

49. A non-transitory computer readable medium comprising program instructions for battery recycling that, when executed by an apparatus, cause the apparatus to perform at least a process of any one of claims 34-48.

50. Active material powder made by the process of any one of claims 34-48.

51. The active material powder of claim 50, further comprising separated aluminum, copper, or a combination thereof.

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