Non-flammable recycling apparatus and method of use thereof

Abstract

This application discloses an apparatus for recycling various devices, including, but not limited to, flammable, reactive, flammable-containing, or electrochemical devices that become flammable or reactive during recycling. Some devices include non-flammable or non-reactive components, such as, but not limited to, non-flammable conveying mechanisms and / or non-reactive conveying mechanisms. This application also discloses methods for using these devices. The methods include means of reducing or eliminating aluminothermic and / or aluminothermic reactions during the processing of the electrochemical devices. In some 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

[0001] Cross-references to related applications

[0002] This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 551,885, filed February 9, 2024, the entire contents of which are incorporated herein by reference for all purposes. Technical Field

[0003] This application relates to the recycling of batteries, battery modules, devices containing batteries, and other related electronic devices and materials. Background Technology

[0004] Batteries, especially rechargeable batteries, are increasingly being used in transportation and electrical equipment applications. For example, lithium-ion batteries, a type of rechargeable battery, are being widely used in various automotive applications, from personal vehicles to autonomous robot fleets, drones, and transportation devices.

[0005] A large number of rechargeable batteries generate waste at the end of their lifespan. Recycling batteries is one solution to this problem. However, battery recycling faces several challenges.

[0006] One challenge is that exothermic reactions can occur during the disassembly, grinding, and separation of batteries and their components. For example, batteries contain various metals, such as, but not limited to, lithium, aluminum, iron, nickel, manganese, cobalt, and zinc. Batteries and devices containing them are ground down to their constituent parts or otherwise reduced in size for further processing. During this process, valuable extracts of high purity, such as graphite or pure nickel and copper, can be extracted. However, the resulting small-sized battery waste may undergo exothermic reactions during grinding, crushing, and disassembly. For example, lithium metal is flammable in air. Finely ground aluminum may undergo an aluminothermic reaction with iron oxide or other metal oxides, such as nickel oxide. Given that batteries contain these metals, highly exothermic reactions are highly likely to occur during battery recycling.

[0007] What is needed are methods and apparatus for detecting, preventing, and mitigating thermal events during battery recycling. This application proposes solutions to the above-mentioned challenges, as well as other challenges in the related fields to which this application pertains. Summary of the Invention

[0008] In one embodiment, this application proposes an apparatus comprising a shredding device coupled to a non-reactive conveying member.

[0009] In a second embodiment, this application proposes a method comprising: conveying flammable material through a device having a shredder as disclosed in this application; detecting a thermal event inside or downstream of the shredder; and stopping or reversing the conveying.

[0010] In a third embodiment, this application proposes a method comprising: conveying battery scrap through the equipment disclosed in this application; and preparing an active material powder.

[0011] In a fourth embodiment, this application proposes a method comprising: conveying a reactive material through an apparatus including a pulverizing device coupled to a non-reactive conveying member; detecting a thermal event inside or downstream of the pulverizing device; and stopping or reversing the conveying.

[0012] Brief description of the attached figures

[0013] Figure 1 An embodiment of a recycling device including a non-reactive conveying structure is shown.

[0014] Figure 2 Another embodiment of a recycling device including a non-reactive conveying structure is shown.

[0015] Figure 3 An embodiment of a pulverizer with conveyor structures located upstream and downstream of the pulverizer is shown.

[0016] Figure 4 An embodiment of a system and method for conveying battery waste through the recycling equipment disclosed in this application is shown.

[0017] Figure 5 An embodiment of the system is shown, in which the crusher hopper and conveyor are equipped with heat and flame detectors.

[0018] Figure 6 The graph shows the temperature of the crusher output chute in Example 2 as a function of time.

[0019] Figure 7 Optical and thermal imaging images of the crusher output chute in Example 2 are shown. Figure 7 In the heatmap at the bottom, blue and black (darker) represent lower temperatures than white, yellow, orange, and red (brighter), the latter representing higher temperatures. The crosshairs in the lower right corner show... Figure 7 Some of the highest temperatures shown.

[0020] Figure 8 Optical and thermal imaging images of the crusher output chute in Example 2 are shown. Figure 8In the heatmap at the bottom, blue and black (darker) represent lower temperatures than white, yellow, orange, and red (brighter), the latter representing higher temperatures. The crosshairs in the lower right corner show... Figure 8 Some of the highest temperatures shown.

[0021] Invention Details

[0022] This application discloses equipment and methods for recycling batteries, battery modules, battery-containing devices, and other related electronic devices and materials, while detecting, mitigating, preventing, or stopping thermal events on or in the processing line.

[0023] definition

[0024] In this application, the phrase "battery waste" refers to used batteries, such as, but not limited to, lithium-ion batteries, devices containing used batteries, and components of used batteries. Battery waste also includes battery manufacturing waste, i.e., waste used in the manufacture of batteries before their actual production is completed. For example, waste generated during battery manufacturing is a type of battery manufacturing waste. Used batteries include, but are not limited to, batteries that have been charged, discharged, or both at least once. Used batteries include, but are not limited to, batteries that have been sold. In some embodiments, battery waste includes only the cathode portion of the battery. In other embodiments, both the cathode and anode of the battery are included in the battery waste. In some embodiments, when the battery contains both cathode and anode materials, the battery waste is calcined to deactivate it.

[0025] In this application, the phrase "lithium-ion battery waste" means battery waste that is from or originates from lithium-ion batteries as defined above.

[0026] In this application, the phrase "active material powder" refers to a portion derived from a pulverized or ground electrochemical battery. The active material powder comprises powders including electrode active materials, polymer binders, and aluminum, nickel, and copper current collectors. The chemical composition of the active material powder depends on the chemical composition of the electrochemical battery waste. The active material powder may contain 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, their oxides, and calcined metal components, as well as combinations thereof.

[0027] In this application, "downstream" refers to a process step or equipment component that follows a process step or equipment part / assembly; "following" here is relative to the direction of material travel on the processing line during the recycling process. The direction of travel does not include the direction of travel when the equipment is reversed after a thermal event.

[0028] In this application, "upstream" refers to a process step or equipment component that precedes a process step or equipment part / assembly; "previous" here is relative to the direction of material travel on the processing line during the recycling process. The direction of travel does not include the direction of travel when the equipment reverses its direction of operation after a thermal event.

[0029] In this application, the phrase "cathode material" refers to the positive electrode component of a battery, including cathode active materials, binders, organic solvents, lithium salts, and lithium-ion conducting materials, as well as combinations thereof. Cathode materials 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.

[0030] In this application, the phrase "anode material" refers to the negative electrode component of a battery, including anode active materials, graphite, and combinations thereof. Anode materials may also include current collector materials such as copper, aluminum, and nickel.

[0031] In this application, the phrase "conveyor component" refers to the part of a processing line that moves material from one point on the line to another.

[0032] In this application, "flammable" means the property of a material to burn and react with oxygen when exposed to heat or exothermic reactions generated by the reactive material described in this application.

[0033] In this application, the phrase "reactive material" refers to a material or group of materials that undergoes an exothermic reaction under solid-state conditions. An example of a reactive material is polished aluminum. Polished aluminum has a high surface area. Therefore, polished aluminum undergoes an aluminothermic reaction with iron oxide, i.e., rust, or Fe₂O₃. One of the products of this aluminothermic reaction is iron (Fe), which is molten due to the energy released accompanying the reaction. Reactive materials can be aluminothermic materials. Aluminothermic materials are materials that react with aluminum metal and / or metal oxides (such as iron oxide, nickel oxide, and other oxides).

[0034] In this application, the phrase "magnetic separation device" refers to a device capable of separating magnetic and non-magnetic materials. For example, a platform with magnets, or a platform with magnets inside, attracts ground iron from a mixture of ground iron, aluminum, and copper. Of these three metals, typically only iron may be magnetic; aluminum and copper are non-magnetic. In a processing line, the collection of materials may contain different types of metals. Magnetic separation devices separate or isolate the magnetic components from the non-magnetic components. As the processing line advances, iron accumulates on the magnets of the magnetic separation device, while the non-magnetic material continues to move through the magnetic separation device. Commercially available magnetic separation devices include, but are not limited to, magnetic drum separators, vibrating feed magnetic plate separators, magnetic plate separators (i.e., in transition chutes), and cross-belt magnetic separators.

[0035] In this application, "non-reactive" means the property of a material not to react with battery waste or its components that have been crushed, disassembled, ground, or reduced in size.

[0036] In this application, "non-flammable" means that the material will not burn or react with oxygen when exposed to heat or exothermic reactions generated by the reactive material described in this application.

[0037] In this application, the phrase "non-reactive conveying member" refers to a portion of a processing line that moves material from one point on the line to another, and that portion is non-reactive as defined in this application. For example, a conveyor belt that moves material on a processing line is a conveying member. Non-reactive conveyor belts, such as belts made entirely of aluminum, are non-limiting examples of non-reactive conveying members. Non-reactive conveyor belts, such as belts made entirely of steel, are non-limiting examples of non-reactive conveying members.

[0038] In this application, the phrase "non-reactive material" refers to a material that does not fall under the category of reactive materials as defined above. Non-reactive materials may include non-reactive metals, such as sheet aluminum. Sheet aluminum does not react with polished aluminum to produce an exothermic reaction. Non-reactive materials may also include composite materials comprising a combination of certain non-flammable refractory components and certain non-reactive metals.

[0039] In this application, the phrase "refractory" refers to the heat resistance and resistance to chemical degradation of nonmetallic materials. Refractory materials also tend to retain strength and rigidity at high temperatures. Some ceramics are considered refractory materials, but metals are not. For example, some ceramics can be heated in air to high temperatures without undergoing any chemical or physical changes. In contrast, metals tend to liquefy when heated in air to high temperatures, and may oxidize if they do not liquefy. Metals have good thermal conductivity, while ceramics generally have poor thermal conductivity. Due to their heat resistance, refractory materials are commonly used in certain kilns, furnaces, reactors, and containers for conveying molten metal.

[0040] In this application, the phrase "thermal event" refers to an exothermic reaction that can be detected by devices such as infrared sensing cameras, thermal detectors, spark detectors, temperature sensors, thermocouples, thermometers, or combinations thereof. Some exemplary devices include, but are not limited to, infrared cameras from Teledyne FLIR. Some exemplary devices include, but are not limited to, spark detectors manufactured by Spectrex and Det-Tronics. Some exemplary devices include, but are not limited to, thermocouples from McMaster Carr, Omega, and other suppliers.

[0041] In this application, the phrase "separated aluminum" refers to high-purity aluminum recovered from battery waste and processed.

[0042] In this application, the phrase "separated copper" refers to high-purity copper recovered from battery waste and processed.

[0043] equipment

[0044] In one embodiment, this application discloses an apparatus comprising a pulverizing device coupled to a non-reactive conveying component. In some recycling processes, metallic components of batteries, such as aluminum, are ground, pulverized, or otherwise reduced in size. This process introduces energy into these components. For example, ground aluminum may react with iron oxide. With sufficient energy introduced, these reduced-size metallic components may initiate exothermic reactions, such as the aluminothermic reaction between aluminum and nickel oxide. An aluminothermic reaction may also occur, where iron oxide (Fe₂O₃) reacts with aluminum to produce iron (Fe) and aluminum oxide (Al₂O₃). Other exothermic reactions are also possible. Exothermic reactions can lead to the spread of exothermic reactions, such as fires involving organic components in a combustion equipment line, such as rubber conveyor belts. To avoid these spreading reactions, the apparatus disclosed in this application does not include components or assemblies that may undergo exothermic reactions or combustion when exposed to heat. An exothermic reaction includes combustion upon contact with reactive materials, such as materials that may initiate aluminothermic reactions or fires. In some embodiments, to avoid these spreading reactions, the equipment disclosed in this application does not include components that could cause exothermic reactions or combustion at processing line locations where aluminothermic reactions, aluminothermic-like reactions, or fires may occur or are likely to occur during battery recycling. For example, the conveyor components near the shredder are made of non-reactive or non-flammable materials, so that if an exothermic reaction is initiated in the shredder, the fire will not spread.

[0045] One embodiment of the device disclosed in this application is as follows: Figure 1 As shown. Figure 1 This shows a processing line starting from the Gaylord Tipper. The Gaylord Tipper is covered by a Hygiene Shroud. A vibratory feeder is mechanically connected to the Gaylord Tipper, allowing material to be transferred from the Gaylord Tipper to the vibratory feeder. Figure 1The illustrated device has a vibrating feeder connected at a right angle to a crusher belt conveyor. This device can be configured in various ways. For example, the vibrating feeder and the crusher belt conveyor can be positioned at different angles relative to each other. Other arrangements are also possible and are within the scope of this application. In some other embodiments, the device may have components connected by straight lines or lines of various curves and angles. The crusher belt conveyor is inclined upwards to move material placed thereon upwards and feed it into the crusher. The crusher includes an internal space that accommodates material falling to the ground, thereby interacting with at least one or more internal crushing mechanisms. When the material exits the crusher, it is conveyed to an impact mill belt conveyor. The impact mill belt conveyor is inclined upwards to move material placed thereon upwards and feed it into the impact mill. In some embodiments, at least the crusher belt conveyor and the impact mill belt conveyor are made of non-reactive materials, non-flammable materials, or materials that are both non-reactive and non-flammable. In other embodiments, components other than the pulverizer metal belt conveyor and the impact mill metal belt conveyor are also made of non-reactive, non-flammable, or both materials. This is to prevent the pulverizer metal belt conveyor and the impact mill metal belt conveyor from catching fire or burning if the pulverizer generates reactive or flammable materials (such as those that trigger thermite or thermite-like reactions).

[0046] In some implementations, including any of the foregoing implementations, the non-reactive conveying member is a non-flammable conveying member.

[0047] In some embodiments, including any of the foregoing embodiments, the conveying member is not under immersion conditions or submerged in water. This means that in some embodiments, the conveying member is exposed to air. In these certain embodiments, the conveying member is not submerged in an inert gas, such as 100% nitrogen or argon. In these certain embodiments, the conveying member is also not operated underwater or under water spray.

[0048] In some implementations, including any of the foregoing implementations, the device is exposed to the atmospheric environment.

[0049] In some embodiments, including any of the foregoing embodiments, the pulverizing device is a pulverizer or a comminutor. In some embodiments, the pulverizing device is a pulverizer. In some embodiments, the pulverizing device is a comminutor. In some embodiments, the pulverizing device is a single-shaft pulverizer. In some embodiments, the pulverizing device is a twin-shaft pulverizer. In other embodiments, the pulverizing device is a four-shaft pulverizer.

[0050] In some embodiments, including any of the foregoing embodiments, the pulverizing device is a pulverizer built into or connected to a sealed fine powder collection box. Fine powder is the product of battery waste being reduced in size, pulverized, or ground. Fine powder includes metals that have been reduced in size, pulverized, or ground.

[0051] In some implementations, including any of the foregoing implementations, the non-reactive conveying component includes a non-flammable conveyor belt.

[0052] In some embodiments, including any of the foregoing embodiments, the non-reactive conveying component includes a non-reactive conveyor belt.

[0053] In some embodiments, including any of the foregoing embodiments, the non-flammable conveying component comprises a non-flammable conveyor belt. In some embodiments, the cleats on the conveyor are made of any kind of metal or alloy thereof. In some of these embodiments, the cleats on the conveyor are made of aluminum or an alloy thereof. In some of these embodiments, the cleats on the conveyor are made of steel. In some embodiments, the cleats are welded to the conveyor. In some embodiments, the cleats are bolted to the conveyor, thereby forming raised barriers between the various sections of the conveyor belt.

[0054] In some implementations, including any of the foregoing implementations, the conveyor belt includes non-flammable wedges.

[0055] In some implementations, including any of the foregoing implementations, the conveyor belt includes non-reactive wedges.

[0056] In some embodiments, including any of the foregoing embodiments, the non-reactive conveying member is made of, or coated with, non-flammable materials selected from the group consisting of: non-flammable metals, non-flammable alloys, non-flammable composite materials, high-temperature resistant metals, high-temperature resistant alloys, refractory materials, and combinations thereof.

[0057] In some embodiments, including any of the foregoing embodiments, the non-reactive conveying member is made of aluminum, iron, steel, or a combination thereof. In some embodiments, including any of the foregoing embodiments, the non-reactive conveying member is made of aluminum. In some other embodiments, including any of the foregoing embodiments, the non-reactive conveying member is made of iron. In some other embodiments, including any of the foregoing embodiments, the non-reactive conveying member is made of steel. In still other embodiments, including any of the foregoing embodiments, the non-reactive conveying member is made of a combination of aluminum, iron, or steel.

[0058] In some embodiments, including any of the foregoing embodiments, the non-reactive conveying member is selected from at least one or more of the following: a conveyor with a non-flammable belt, a drag conveyor, a vibrating feeder with a non-flammable trough, an auger, and combinations thereof. Depending on the equipment, the non-reactive conveying member may be a conveyor with a non-flammable belt. In some other embodiments, the non-reactive conveying member is a drag conveyor. In some other embodiments, the non-reactive conveying member is a vibrating feeder. In some other embodiments, the non-reactive conveying member is a non-flammable trough. In some other embodiments, the non-reactive conveying member is an auger.

[0059] In some implementations, because high temperatures may be present during an aluminothermic event, any component directly exposed to the reactive material, as well as any nearby components, are non-flammable, non-reactive, or both.

[0060] Figure 2 The image shown is an example of a fire mitigation component for a device. Figure 2 The equipment shown is Figure 1 Same, but Figure 2 It also shows the location of the dust collection point.

[0061] Figure 2 The illustrated equipment includes means for reducing the likelihood of fire or thermal events. These means include a feed controller capable of minimizing the amount of material in the crusher hopper. These means also include devices for visually inspecting foreign objects (e.g., cameras). These means also include devices for magnetically separating foreign objects (e.g., magnetic separators).

[0062] Figure 2 The illustrated device includes means for controlling any thermal events that may occur. It eliminates the use of rubber belt conveyors and employs an all-metal design for both the conveyor and crusher hoppers. The device may include sacrificial or replaceable metal conveyor pans.

[0063] Figure 2 The apparatus shown includes means for detecting thermal events and for cooling thermal events. These means include infrared cameras, spark detectors, temperature sensors, and combinations thereof.

[0064] In some implementations, including any of the foregoing implementations, the non-flammable tank is made of Cu, refractory materials, or a combination thereof.

[0065] In some other embodiments, including any of the foregoing embodiments, the non-flammable tank is made of aluminum, iron, steel, or a combination thereof.

[0066] In some implementations, including any of the foregoing implementations, at least one non-reactive conveying member is connected downstream of the crushing device.

[0067] In some implementations, including any of the foregoing implementations, the crushing device is connected to the milling device via a metal belt conveyor.

[0068] In some implementations, including any of the foregoing implementations, the grinding device is an impact mill.

[0069] In some implementations, including any of the foregoing implementations, a non-flammable conveying component is connected to a vibrating feeder.

[0070] In some implementations, including any of the foregoing implementations, the vibrating feeder is connected to the Gaylord dumper.

[0071] In some embodiments, including any of the foregoing embodiments, the device further includes at least one means for detecting thermal events.

[0072] In some implementations, including any of the foregoing implementations, the at least one device for detecting thermal events is selected from: an infrared sensor camera, a linear heat detector laid along the entire length of the conveyor, a spark detector, a temperature sensor, a thermocouple, a thermometer, and combinations thereof.

[0073] In some implementations, including any of the foregoing implementations, the at least one device for detecting thermal events is an ultraviolet-infrared (UV-IR) camera.

[0074] In some implementations, including any of the foregoing implementations, the at least one device for detecting thermal events is a flame detector.

[0075] In some embodiments, including any of the foregoing embodiments, one of the at least one device for detecting thermal events is located on the interior and vertical sidewall of the crushing device, the interior and top of the crushing device, the interior and bottom of the crushing device, at the crusher inlet, at the crusher discharge chute and conveyor, at the discharge conveyor connected to the impact mill, or a combination thereof.

[0076] In some embodiments, including any of the foregoing embodiments, one of the at least one device for detecting thermal events is positioned at the bottom of the non-reactive conveying member.

[0077] In some embodiments, including any of the foregoing embodiments, the equipment is not enclosed in an atmosphere containing an inert gas. In some embodiments, the inert gas is nitrogen (N2) gas with an oxygen (O2) content of less than 18%. In some embodiments, the inert gas is argon (Ar). In some embodiments, the inert gas is a combination of N2, O2, and Ar.

[0078] In some embodiments, including any of the foregoing embodiments, the equipment 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 combinations thereof. These means include, but are not limited to, vacuum cleaners, blowers, collection boxes, filters, and combinations thereof.

[0079] In some implementations, including any of the foregoing implementations, the equipment also includes a dumper, a vibrating feeder, or a combination thereof.

[0080] In some implementations, including any of the foregoing implementations, the vibrating feeder also includes a vibrating feed speed controller.

[0081] In some embodiments, including any of the foregoing embodiments, the equipment also includes a feed controller for controlling the amount of material in the crushing unit.

[0082] In some embodiments, including any of the foregoing embodiments, the equipment further includes a sorting conveyor connected to a pulverizer metal belt conveyor, wherein the pulverizer metal belt conveyor is connected upstream of the pulverizing unit.

[0083] In some implementations, including any of the foregoing implementations, the shredder metal belt conveyor is inclined, and the shredding device is higher than the sorting conveyor.

[0084] In some embodiments, including any of the foregoing embodiments, the apparatus further includes at least one magnetic separation device.

[0085] In some embodiments, including any of the foregoing embodiments, at least one magnetic separation device is positioned immediately in front of the milling device.

[0086] In some embodiments, including any of the foregoing embodiments, at least one magnetic separation device is positioned immediately in front of the shredder metal belt conveyor.

[0087] In some implementations, including any of the foregoing implementations, the equipment feed capacity is configured to be at least 2 metric tons per hour. This means that the equipment can process a material volume of at least 2 metric tons per hour. In some instances, the volume is less than 1,000 metric tons or less than 100 metric tons.

[0088] method

[0089] In some embodiments, this application proposes a method comprising: conveying reactive material through the apparatus disclosed in this application; detecting thermal events inside or downstream of the pulverizer; and stopping or reversing the conveying.

[0090] In some embodiments, this application proposes a method comprising: conveying reactive material through the apparatus disclosed in this application; detecting thermal events inside or downstream of the pulverizer; and reversing the conveying to dump or remove certain hot material from the tail of the conveyor. In some embodiments, the hot material may be deposited into a containment area. In some embodiments, the hot material may be deposited in a sand box.

[0091] In some embodiments, this application proposes a method comprising: conveying battery waste through the equipment disclosed in this application; and preparing an active material powder. In some embodiments, the active material powder can be prepared simply by crushing. In other embodiments, the active material powder is prepared by both crushing and calcination.

[0092] In some embodiments, this application proposes a method comprising: conveying a reactive material through an apparatus including a pulverizing device coupled to a non-reactive conveying member; detecting a thermal event inside or downstream of the pulverizing device; and stopping or reversing the conveying.

[0093] In some embodiments, this application proposes a method comprising: conveying a reactive material through an apparatus including a pulverizing device coupled to a non-reactive conveying member; detecting a thermal event inside or downstream of the pulverizing device; and stopping the conveying.

[0094] Implementation schemes of certain methods

[0095] The following steps can be found Figure 4Implemented in the system shown. For example, Figure 4 A box of battery waste (401) is shown, the contents of which are conveyed to a box dumper (402), then to a crusher (403), and then to a feed conveyor (404). Figure 4 The image shows a feed conveyor (404) feeding some material to an impact mill (406), from which copper (Cu) and aluminum (Al) are separated (407). Figure 4 The image shows the feed conveyor delivering some material to the magnetic separator (405).

[0096] In some embodiments, lithium-ion battery (LIB) waste is used as feed material and then processed into active material powder. The lithium-ion battery waste will primarily comprise cathode waste material of various shape factors, but other lithium-ion battery waste is also covered within the scope of this application. In some embodiments, lithium-ion battery waste bins are transported by forklift to a bin dumper. The waste bins are poured from the dumper into a vibrating feeder. In some instances, the lithium-ion battery waste bins are dumped into a hopper above the vibrating feeder. In some embodiments, the waste material is conveyed from the feeder to a crusher feed conveyor, which is a metal belt conveyor that feeds the material into the crusher. This metal belt conveyor is an example of a non-reactive conveying component. An all-metal vibrating feeder is an example of a non-reactive conveying component. An all-metal plate feeder is an example of a non-reactive conveying component. An all-metal drag conveyor is an example of a non-reactive conveying component.

[0097] In some embodiments, the pulverized material is conveyed to the impact mill via another metal belt conveyor, an impact mill feed conveyor, for further size reduction. In some embodiments, the mill product is pneumatically conveyed to the cyclone separator stage. The underflow from the cyclone separator enters the screening stage, while the overflow is conveyed by a blower stage and a dust collector.

[0098] In some implementations, oversized particles from the upper screen of the screening stage are sent to a bailing station. Oversized particles from the lower screen are fed into a delamination mill, whose output is pneumatically conveyed to another cyclone separator stage. Smaller particles from the lower screen are conveyed to the powder storage area by a screener screw conveyor and a powder silo screw conveyor.

[0099] In some implementations, an air table is used to separate aluminum and copper foil, with the heavier material sent to a copper bagging station and the lighter material sent to an aluminum bagging station. The finer material from the screening stage is conveyed by a screening machine screw conveyor and a powder silo screw conveyor to a powder storage silo, where, in some implementations, the active material powder accumulates.

[0100] In some embodiments, the powder storage silo feeds the active material powder into a powder feeder, which is a loss-in-weight system. In some embodiments, the feeder feeds the powder into a slurry screw conveyor, which leads to an active material powder slurry tank.

[0101] In some implementations, at least one or more dust collectors discharge material via airlocks to a dust collector screw conveyor, which then feeds into a powder silo screw conveyor.

[0102] In some implementations, dust collection vents are placed in the following areas: Gaylord unloading hood; vibrating feeder; feed conveyor; crusher housing; crushed material feed conveyor; magnetic separator box; vibrating screen for sieving; air table; large-size plastic bagging station; aluminum loadout bagging station; copper loadout bagging station; active material powder silo-silo ventilation filter; powder loadout bagging station; active material powder slurry tank; and bag unloading machine tie / untie box.

[0103] An example device such as Figure 3 As shown. Figure 3 A non-reactive conveying member made of metal is shown, which conveys reactive materials (such as lithium-ion battery waste) upwards and into a closed shredder. Devices for sensing thermal events, such as infrared cameras, linear thermal detectors, spark detectors, temperature sensors, thermocouples, thermometers, or combinations thereof, can be mounted above the shredder at any practically feasible location to allow for full observation of the shredding process.

[0104] For example, see Figure 5 It displays a range of detection devices, such as a FLIR process camera, a Det-Tronics triple infrared detector, and a linear thermal detector. Figure 5 The image shows a FLIR infrared camera at the feed inlet of the crusher. Figure 5A linear thermal detector is shown along the conveyor leading to the impact mill. Figure 5 The image shows two FLIR and triple infrared (infrared camera) detectors and a flame detector at the crusher discharge chute and conveyor. Figure 5 The image shows two FLIR and triple infrared detectors and a flame detector at the discharge conveyor leading to the impact mill. Figure 5 The equipment may also include a fire alarm linkage device. This linkage device includes linear thermal detectors along the two conveyors, which are triggered when a threshold temperature is sensed. Below the pulverizer is another non-reactive conveying component that receives the pulverized material and conveys it upwards to the impact mill.

[0105] In some implementations, material from the dump hopper falls onto a vibrating feeder, which disperses the material, facilitating metering and ensuring a uniform feed rate to downstream equipment. If necessary, a viewing channel can be provided to inspect the contents of the Gaylord hopper and remove foreign objects. The material on the feeder is then transferred to a feed conveyor. The vibrating feeder is equipped with two motors, controlled by a single variable frequency drive (VFD).

[0106] In some implementations, a conventional (i.e., optical, video) camera monitors the vibrating feeder.

[0107] In some implementations, material from a vibrating feeder is transferred to a metal belt conveyor, which transports the material to the crusher. This conveyor provides a visual passage for identifying and removing foreign objects (if necessary).

[0108] In some implementations, the feed conveyor is equipped with a VFD to control the motor speed.

[0109] In some implementations, a pull rope is installed along the length of the conveyor as an emergency stop device.

[0110] In some implementations, linear thermal detectors are laid along the length of the conveyor.

[0111] In some implementations, a zero-speed sensor switch is used to detect whether the motor is running and whether the conveyor belt has stopped.

[0112] In some implementations, a photo-eyelevel sensor is installed on the crusher hopper for high-level detection, and a paddle switch is installed at the discharge chute to monitor the height of the process material.

[0113] In some implementations, FLIR cameras are used. In other implementations, these cameras are used as process cameras and for temperature distribution monitoring.

[0114] In some implementations, infrared cameras are used for flame detection and are the primary source of fire detection during the process.

[0115] In some implementations, the shredder can detect jamming. In the event of jamming, in some implementations, it will reverse the direction of the cutting blades and restart normal operation. In some implementations, it will complete this cycle up to three times to clear the machine of the jam. If the shredder is still jammed after three cycles, the equipment will sound an alarm and stop. In some implementations, manual clearing of the jam is required at this point.

[0116] In some implementations, the pulverized material is fed from a feed conveyor into an impact mill for further size reduction.

[0117] In some implementations, the pneumatic conveying system is started before the impact mill is started. In some implementations, water is sprayed into the impact mill as needed to control the chamber temperature. In some implementations, water spraying is started once the high temperature limit (UL) is reached and stops when the low temperature limit (LL) is reached. In some implementations, the impact mill is shut down in the event of extremely high temperatures.

[0118] In some implementations, the impact mill chamber and spindle bearings are equipped with temperature indicators to monitor operating conditions.

[0119] In some implementations, the finer material from the first screen of the screening class is fed into the metering hopper of the stripping mill, which is equipped with a rotary airlock. The ground waste is then fed into the stripping mill from the rotary airlock.

[0120] In some embodiments, the vibrating screen receives feed from a rotary airlock. In some embodiments, oversized material (typically plastic) from the upper screen (+3 mesh) is fed to a large-size pellet baling station. In some embodiments, oversized material from the second screen (+60 mesh) is fed into the metering chute of the stripping mill. In some embodiments, finer material (-60 mesh) from the second screen is fed into the screen's screw conveyor.

[0121] In some implementations, the dust collector is connected to the top screen to generate a slight airflow to prevent material from seeping out over time.

[0122] In some embodiments, the screening machine receives feed from the stripping mill and separates aluminum and copper from the active material powder. In some embodiments, the screening machine starts automatically once the stripping mill system is started. In some embodiments, blockage detection sensors are located at the bottom of the equipment transition section. If these sensors detect any blockage causing material overflow in downstream equipment, they can signal to stop the stripping system.

[0123] In some implementations, the aluminum and copper materials separated by the screening machine are conveyed to an air stage. In some implementations, the air stage then separates the aluminum and copper. In some implementations, the air stage starts automatically once the screening stage is operational. In some instances, this step produces separated aluminum, copper, or both.

[0124] In other embodiments, this application proposes a non-transitory computer-readable medium comprising program instructions for battery recycling. When executed by a device, it causes the device to perform at least one method disclosed in this application.

[0125] Active material powder

[0126] Active material powder manufactured by the method of this application.

[0127] In some embodiments, the active material powder also includes isolated aluminum, copper, or a combination thereof.

[0128] In some implementations, the active material powder is produced together with isolated aluminum, copper, or a combination thereof. Example

[0129] Example 1 — Battery Recycling

[0130] In this embodiment, several metric tons (mt) of battery waste were processed. The Gaylord loading rate (in minutes) displayed by the equipment used is shown in Table 1 below as a function of throughput [metric tons / hour (h)] and Gaylord weight. Table 1

[0131]

[0132] The cathode material for lithium-ion batteries is pulverized, followed by two-stage granulation and sieving to produce -60 mesh active material powder feedstock.

[0133] The equipment includes the following devices: a bulk bag unloader; a powder bag unloader conveyor; a vibrating feeder; a crusher feed conveyor; and an impact mill feed conveyor.

[0134] Example 2 — Detection of Thermal Events

[0135] This example illustrates a high-temperature event at the discharge port of the crusher.

[0136] Continuous grinding of lithium-ion battery cathode waste. See also Figure 6 The thermal imager detected that the temperature of the material being crushed had risen above 400°C. Prior to observing the peak exceeding 400°C, several temperature spikes of approximately 100°C were also observed. This triggered the interlock device, stopping the crusher. The thermal event did not spread.

[0137] Figure 6 The three temperature curves in the image show the temperatures at three locations monitored by a FLIR camera during the process. These three locations are the crusher hopper, the crusher outlet, and the conveyor outlet of the crusher-impact mill.

[0138] Figure 7 and Figure 8 Images from two subsequent time points are shown. The top image shows the crusher hopper, and the bottom image shows the crusher outlet (thermal view).

[0139] Figure 7 This indicates the start of a thermal event. Figure 8 The display showed that the peak temperature appeared at the pulverizer outlet several seconds later.

[0140] A thermal event was detected. This event may have damaged some chain links. However, the thermal event stabilized and cooled without human intervention. The thermal event did not spread or propagate. There was no apparent damage to the conveyor belt. See also Figure 7 and Figure 8 .

[0141] The above embodiments and examples are for illustrative purposes only and not for limitation. Those skilled in the art will recognize or be able to identify numerous equivalents of specific compounds, materials, and procedures through experiments not exceeding conventional methods. All such equivalents are considered to be within the scope of the claims.

[0142] All publications and patent applications referenced in this specification are incorporated herein 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 according to various embodiments, those skilled in the art will understand that various modifications, substitutions, omissions, and alterations may be made without departing from its spirit. Therefore, it is intended that the scope of the claimed subject matter be limited only by the scope of the appended claims (including their equivalents).

Claims

1. An apparatus comprising a pulverizing device connected to a non-reactive conveying member.

2. The device according to claim 1, wherein the non-reactive conveying component is a non-flammable conveying component.

3. The device according to claim 1 or 2, wherein the conveying member is not under immersion conditions or is submerged in water.

4. The device according to any one of claims 1 to 3, wherein the device is exposed to the atmospheric environment.

5. The equipment according to any one of claims 1 to 4, wherein the pulverizing device is a pulverizer or a grinding mill.

6. The apparatus according to any one of claims 1 to 5, wherein the pulverizing device is a pulverizer built into or connected to a sealed fine powder collection box.

7. The device according to any one of claims 1 to 6, wherein the non-reactive conveying component comprises a non-flammable conveyor belt, and is composed of or substantially composed of a non-flammable conveyor belt.

8. The device according to claim 7, wherein the conveyor belt comprises non-flammable wedges.

9. The device according to any one of claims 1 to 8, wherein the non-reactive conveying member is made of, or coated with, the following non-reactive materials: non-reactive metals, non-reactive alloys, non-reactive composite materials, high-temperature resistant metals, high-temperature resistant alloys, refractory materials, and combinations thereof.

10. The device according to any one of claims 1 to 9, wherein the non-reactive conveying member is made of, or coated with, the following non-flammable materials: non-flammable metals, non-flammable alloys, non-flammable composite materials, high-temperature resistant metals, high-temperature resistant alloys, refractory materials, and combinations thereof.

11. The device according to any one of claims 1 to 10, wherein the non-reactive conveying member is made of aluminum, iron, steel, stainless steel, carbon steel or a combination thereof.

12. The device according to any one of claims 1 to 11, wherein the non-reactive conveying component is selected from at least one or more of the following components: a conveyor with a non-flammable belt, a drag conveyor, a vibrating feeder with a non-flammable trough, a screw conveyor, and combinations thereof.

13. The apparatus of claim 12, wherein the non-flammable tank is made of Cu, refractory material or a combination thereof.

14. The apparatus according to any one of claims 1 to 13, wherein at least one non-flammable conveying component is connected downstream of the crushing device.

15. The apparatus according to any one of claims 1 to 14, wherein the crushing device is coupled to the grinding device, and the grinding device is coupled to the metal belt conveyor.

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

17. The apparatus according to any one of claims 1 to 16, wherein the non-reactive conveying member is coupled to a vibrating feeder.

18. The apparatus of claim 17, wherein the vibrating feeder is coupled to the Gaylord dumper.

19. The apparatus according to any one of claims 1 to 18, further comprising at least one means for detecting thermal events.

20. The apparatus of claim 19, wherein the at least one means for detecting thermal events is selected from: an infrared sensor camera, a linear thermal detector laid along the entire length of the conveyor, a spark detector, a temperature sensor, a thermocouple, a thermometer, and combinations thereof.

21. The apparatus according to any one of claims 19 or 20, wherein one of the at least one means for detecting thermal events is located on the interior and vertical sidewall of the crushing apparatus, the interior and top of the crushing apparatus, the interior and bottom of the crushing apparatus, at the crusher inlet, at the crusher discharge chute and conveyor, at the discharge conveyor connected to the impact mill, or a combination thereof.

22. The device according to any one of claims 19 to 21, wherein one of the at least one means for detecting thermal events is located at the bottom of the non-reactive conveying member.

23. The device according to any one of claims 1 to 22, wherein the device is not enclosed in an atmosphere containing an inert gas.

24. The apparatus according to any one of claims 1 to 23 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 combinations thereof.

25. The equipment according to any one of claims 1 to 24 further includes a dumper, a vibrating feeder, or a combination thereof.

26. The apparatus of claim 25, wherein the vibrating feeder further comprises a vibrating feed speed controller.

27. The apparatus according to any one of claims 1 to 26, further comprising a feed controller for controlling the amount of material in the crushing device.

28. The apparatus according to any one of claims 1 to 27, further comprising a sorting conveyor connected to the pulverizer metal belt conveyor, wherein the pulverizer metal belt conveyor is connected upstream of the pulverizing device.

29. The apparatus of claim 28, wherein the pulverizer metal belt conveyor is inclined, and the pulverizing device is positioned above the sorting conveyor.

30. The apparatus according to any one of claims 1 to 29 further includes at least one magnetic separation device.

31. The apparatus of claim 30, wherein the at least one magnetic separation device is disposed immediately in front of the grinding device.

32. The apparatus according to any one of claims 1 to 31 further includes at least one magnetic separation device disposed immediately in front of the metal belt conveyor of the crusher.

33. The equipment according to any one of claims 1 to 32, wherein the feeding capacity of the equipment is at least 2 metric tons / hour.

34. A method comprising: The reactive material is conveyed through the apparatus according to any one of claims 1 to 33; Detecting thermal events inside or downstream of the pulverizer; as well as Stop or reverse the conveying.

35. A method comprising: Battery waste is transported through the device according to any one of claims 1 to 33; as well as Prepared into active material powder.

36. A method comprising: A reactive material is conveyed through a device, the device including a crushing device connected to a non-reactive conveying component; Detecting thermal events inside or downstream of the pulverizing device; as well as Stop the delivery.

37. The method according to any one of claims 34 to 36, wherein the reactive material is a flammable material.

38. The method according to any one of claims 34 to 37, wherein the reactive material is lithium-ion battery waste, calcined lithium-ion battery waste, its components, or a battery pack, module, or device containing lithium-ion batteries.

39. The method according to any one of claims 34 to 38, wherein the reactive material is a cathode material or a derivative thereof after processing.

40. The method according to any one of claims 34 to 39, wherein the reactive material is conveyed into the crushing apparatus on a metal belt conveyor.

41. The method according to any one of claims 34 to 40, wherein the reactive material is conveyed from a feeder to a metal belt conveyor, the metal belt conveyor feeding the material into the crushing device.

42. The method according to any one of claims 34 to 41, wherein detecting a thermal event comprises detecting a rapid temperature rise in the reactive material, detecting a temperature above 100°C in the reactive material, detecting a temperature above 150°C in the reactive material, or a combination thereof.

43. The method of claim 42, further comprising: automatically shutting down the crushing apparatus; reversing at least one conveyor; automatically shutting down the dust collector; drawing dust from the conveyor; automatically shutting down the impact mill; automatically shutting down the feeding system; automatically shutting down the blower that conveys material into or through the impact mill located downstream of the crushing apparatus; automatically shutting down the blower that conveys material into or through the stripping mill; automatically activating the component interlocking device in the method to stop the method; and using an alarm device consisting of a horn, alarm, beacon light, flashing light, or a combination thereof.

44. The method according to any one of claims 34 to 43, wherein stopping the method comprises activating the pull cord.

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

46. ​​The method according to any one of claims 34 to 45, wherein stopping the method comprises shutting down all operations except the dust collector.

47. The method according to any one of claims 37 to 46, wherein the method produces an active material powder.

48. The method according to any one of claims 37 to 47, wherein the method produces an active material powder and separated aluminum, copper or a combination thereof.

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

50. An active material powder manufactured by the method according to any one of claims 34 to 48.

51. The active material powder according to claim 50 further comprises separated aluminum, copper, or a combination thereof.

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