System and method to shred and process battery under inert environment

Abstract

The present disclosure discloses a system (102) and a method (200) for shredding and processing batteries under an inert environment includes a first hopper (104) to receive batteries to be recycled. A conveyor belt (106) connected to first hopper (104) transports the batteries to second hopper (108). An air-tight chamber (110) receives batteries through the second hopper (108) and includes a first valve (110-1) to allow entry of the batteries and a second valve (110-2) to transfer the batteries to a shredder (112) to shred the batteries into pieces. A nitrogen assembly (114) supplies gaseous nitrogen into air-tight chamber (110) to create and maintain an inert environment. A hammer mill (116) crushes shredded pieces into fine particles. A heating chamber (118) applies heating to evaporate electrolyte from the fine particles. A rotary airlock valve (120) and a vibrating screen (122) regulate and separate processed material.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of battery recycling. In particular, the present disclosure pertains to a system for safe and efficient shredding and processing of lithium-ion batteries, specifically the system and a method to shred and process batteries under an inert environment.BACKGROUND

[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.

[0003] Advances in battery technology have led to a growing focus on sustainable and efficient methods for handling rechargeable energy storage systems. With the expanding global use of lithium-ion batteries across various applications, there is an increasing need to address the challenges associated with battery end-of-life processes. Batteries, due to their chemical composition and energy density, require careful handling during recycling to mitigate risks such as thermal runaway and inadvertent chemical reactions. Industry stakeholders are tasked with finding solutions that not only preserve materials but also enhance safety and environmental protection during dismantling and recovery operations.

[0004] Existing recycling techniques recover components and materials while ensuring that environmental impacts and operational hazards are minimized. In applications ranging from consumer electronics to electric vehicles, the recovery of metals and chemicals from spent batteries is important for resource sustainability. However, many of the methods employed today require multiple preparatory steps and intensive safety measures, which increase both the complexity and cost of recycling operations. There is a clear requirement within the industry to develop processing steps that not only simplify the workflow but also enhance throughput without compromising safety. A robust and efficient processing system could lead to improved material recovery rates and contribute to a more sustainable lifecycle for energy storage devices.

[0005] Existing processes for recycling batteries often involve cumbersome procedures that necessitate the discharging of batteries and extensive safety protocols. Such conventional methods, while having contributed to significant advancements in material recovery, are sometimes limited by multi-step operations that increase the risk of encountering thermal or chemical hazards during dismantling operations. The handling and treatment of sensitive battery components demand a balance between operational efficiency and the stringent control of adverse reactions such as overheating or gas release. Such complexity not only escalates the cost of recovery but may also extend the duration of recycling operations. As a result, the need for solutions that streamline such operations while significantly reducing associated hazards is increasingly evident.

[0006] A significant challenge in modern battery recycling is the effective management of hazardous conditions arising during battery dismantling and material recovery. Many existing methods have limitations that can lead to inefficiencies and potential safety issues during high-energy manipulation of components. The specific difficulties include the need to maintain controlled conditions that prevent unwanted chemical and thermal reactions, thereby preserving both the integrity of recycled materials and the safety of the process environment. In some cases, handling measures that minimize risks result in extended operational cycles or require additional infrastructure, which affects economic viability. Such issues underscore the importance of developing improved approaches that address safety concerns, achieve quicker processing rates, and enable a more sustainable recovery of battery components.

[0007] Current recycling technologies for lithium-ion batteries often involve complex processes that require the batteries to be fully discharged before processing. This step is necessary to prevent short circuits and potential fires during the mechanical shredding and separation stages. However, the discharge process is time-consuming and costly, adding to the overall expense of battery recycling. Additionally, existing methods may not effectively recover all important materials, such as lithium, cobalt, and nickel, which are essential for the production of new batteries. The inefficiency in material recovery further exacerbates the environmental impact and economic viability of current battery recycling practices.

[0008] Patent document, "CN 119,092,871 A" titled "A method for fully recycling negative electrode materials of waste lithium batteries" discloses a method wherein waste lithium batteries are charged disassembled and crushed in an inert gas atmosphere to obtain negative electrode materials, which are treated in solvent A to obtain negative electrode material solids and electrolytes. The obtained solids are treated in solvent B to obtain negative electrode copper sheets, negative electrode powder containing elemental lithium, and a binder. The negative electrode powder containing elemental lithium is added to solvent C for further treatment to obtain negative electrode graphite powder and lithium carbonate. The method of the present invention has mild conditions, is easy to operate, has a simple process, does not require complex equipment, and the parameters of each process are easy to achieve. It has the advantages of high efficiency, no pollution, and a high recovery rate. The solvent used can be recycled and reused, which is green and environmentally friendly, and has high resource utilization.

[0009] Another patent document, "CN 107024662 A", titled "A kind of analysis test method of charging and discharging lithium battery performance and Mechanism of electrochemical behaviors of anhydrous" discloses a kind of charging and discharging lithium battery performance and the analysis test method of Mechanism of electrochemical behaviors of anhydrous, its technical characteristic is: Comprise the following steps- Step 1, electrode active material particles are fabricated to after electrode of lithium cell the electrode of lithium cell is assembled into lithium battery, Step 2, to lithium battery enter pretreatment, Step 3, lithium battery is subjected to charging and discharging lithium battery performance test under different temperatures and different electric current, Step 4, the cut-out point that charging and discharging lithium battery process is set, Step 5, disassemble in inert gas environment lithium battery and stripping electrode, Step 6, under different cut-out points lithium battery electrode plate carry out X ray diffraction analysis, detection electrode of lithium cell discharge and recharge product change, Step 7, the reaction mechanism equation according to different cut-out points, so as to infer the mechanism of electrode reaction. The prior art can effectively judge the degree that change of the active material in charge and discharge process, electrochemical reaction is carried out, and then can study the discharge and recharge reaction mechanism of battery.

[0010] Hence, in view of the aforementioned challenges and shortcomings in prior art, there is a dire need in the art to provide a system and a method of shredding and processing batteries under an inert environment.OBJECTS OF THE PRESENT DISCLOSURE

[0011] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.

[0012] It is a general object of the present disclosure to overcome the limitations of existing systems of battery recycling systems and methods.

[0013] It is an object of the present disclosure to provide a system for shredding and processing batteries under an inert environment and a method thereof.

[0014] It is another object of the present disclosure to provide a system that operates under an inert atmosphere to prevent fires and chemical reactions during the shredding and processing of lithium-ion batteries, thereby ensuring a safer recycling environment.

[0015] Yet another object of the present disclosure is to provide a system and a method that allows batteries to be processed without the need for pre-discharge, reducing the time and cost associated with traditional recycling methods.

[0016] Yet another object of the present disclosure is to provide a system and a method that maximizes the recovery of valuable materials such as lithium, cobalt, nickel, and graphite from end-of-life batteries, contributing to resource sustainability and reducing the need for raw material extraction.

[0017] Yet another object of the present disclosure is to provide a system that integrates mechanical and thermal processes to simplify the workflow, enhance throughput, and improve the overall efficiency of battery recycling operations.

[0018] Yet another object of the present disclosure is to minimize the ecological footprint of battery recycling by preventing the release of hazardous substances and promoting the reuse of recovered materials in new battery production.SUMMARY

[0019] Within the scope of this application, it is expressly envisaged that the various aspects, embodiments, examples, and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.

[0020] Aspects of the present disclosure relate to the field of battery recycling. In particular, the present disclosure pertains to a system for safe and efficient shredding and processing of lithium-ion batteries, specifically a system and a method to shred and process batteries under an inert environment.

[0021] In an aspect, the present disclosure, the system includes a first hopper to receive batteries for recycling. A conveyor belt is coupled to the first hopper to transport the batteries to a second hopper. An air-tight chamber receives the batteries through the second hopper. The air-tight chamber includes a first valve positioned to allow entry of the batteries and a second valve positioned to transfer the batteries to a shredder. The shredder is positioned beneath the air-tight chamber to shred the batteries into pieces.

[0022] In an aspect, a nitrogen assembly supplies gaseous nitrogen into the air-tight chamber to create and maintain an inert environment. A hammer mill is mechanically coupled to the shredder to crush the shredded pieces into fine particles. A heating chamber is coupled to the hammer mill to apply heating to evaporate the electrolyte from the fine particles, resulting in an electrolyte-free material. A rotary airlock valve is coupled to the heating chamber to regulate the transportation of the electrolyte-free material while maintaining the inert environment. A vibrating screen is mechanically coupled to the rotary airlock valve to separate the electrolyte-free material from residual material.

[0023] In another aspect, the nitrogen assembly includes a tank to store fluid nitrogen, an evaporator to convert the fluid nitrogen into gaseous nitrogen, and an inlet to supply the gaseous nitrogen to the air-tight chamber. The evaporator is coupled to the tank and the inlet.

[0024] In yet another aspect, the shredder includes multiple shafts with cutting blades to shred the battery. The heating chamber is a closed chamber, and heating is applied through one or more means selected from thermic fluid heating, electric heating, microwave heating, infrared (IR) heating, and hot air circulation (convection heating). The first valve is positioned at the top side of the air-tight chamber, and the second valve is positioned at the bottom side of the air-tight chamber.

[0025] In yet another aspect, the system further includes an electrolyte suction apparatus positioned at the top side of the heating chamber to extract the evaporated electrolyte vapors.

[0026] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.BRIEF DESCRIPTION OF DRAWINGS

[0027] The accompanying drawings, which are incorporated herein, and constitute a part of this disclosure, illustrate exemplary embodiments of the disclosed methods and systems which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale; emphasis is instead placed upon clearly illustrating the principles of the present disclosure. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that the disclosure of such drawings includes the disclosure of electrical components, electronic components or circuitry commonly used to implement such components.

[0028] FIG. 1 illustrates an exemplary representation of a block diagram of a system to shred and process batteries under an inert environment, in accordance with an exemplary embodiment of the present disclosure.

[0029] FIG. 2 illustrates an exemplary representation of a method of shredding and processing batteries under the inert environment, in accordance with an exemplary embodiment of the present disclosure.

[0030] FIG. 3 illustrates an exemplary representation of process layout illustrating the overall working of the proposed system, in accordance with an exemplary embodiment of the present disclosure.

[0031] Other objects, advantages, and novel features of the disclosure will become apparent from the following more detailed description of the present embodiment when taken in conjunction with the accompanying drawings.DETAILED DESCRIPTION

[0032] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0033] The present disclosure relates to the field of battery recycling. In particular, the present disclosure pertains to a system for safe and efficient shredding and processing of lithium-ion batteries, specifically the system and a method to shred and process batteries under the inert environment.

[0034] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the accompanying drawings FIGs. 1-3.

[0035] FIG. 1 illustrates an exemplary representation of a block diagram (100) of a system (102) to shred and process batteries under an inert environment, in accordance with an exemplary embodiment of the present disclosure.

[0036] In an embodiment of the present disclosure, a system (102) can include a first hopper (104) to receive batteries to be recycled. The first hopper (104) can be designed to accommodate batteries of various sizes and types, ensuring efficient handling before processing. The first hopper (104) can be structured with sloped or guided surfaces to facilitate the smooth movement of batteries toward a conveyor belt (106) (the terms "conveyor belt" and "cover belt" are used interchangeably).

[0037] In an embodiment, the conveyor belt (106) can be connected to the first hopper (104) and can transport the batteries to a second hopper (108). The conveyor belt (106) can be motorized and can operate at variable speeds to control the flow of batteries entering the second hopper (108). The conveyor belt (106) can include surface grips or adjustable barriers to prevent misalignment or clogging of the batteries during transportation.

[0038] In such embodiment, the second hopper (108) can be positioned above an air-tight chamber (110) and can serve as an intermediary storage unit before the batteries enter the air-tight chamber (110). The air-tight chamber (110) can be designed to prevent external atmospheric exposure and maintain an inert environment for safe battery processing. The air-tight chamber (110) can include a first valve (110-1), which can be positioned to allow entry of the batteries when open. The first valve (110-1) can be a pneumatically controlled or electronically actuated valve that ensures controlled and sequential entry of batteries.

[0039] In such embodiment, the air-tight chamber (110) can further include a second valve (110-2), which can be positioned to transfer the batteries to a shredder (112) when open. The second valve (110-2) can be configured to prevent leakage of gases or exposure of the chamber (110) to external contaminants. The shredder (112) can be positioned beneath the air-tight chamber (110) and can shred the batteries into pieces. The shredder (112) can include multiple shafts (112-1) equipped with cutting blades that can effectively break down the battery casings and internal components into smaller pieces for further processing.

[0040] In such embodiment, the system (102) can include a nitrogen assembly (114) to supply gaseous nitrogen into the air-tight chamber (110) to create and maintain the inert environment. The nitrogen assembly (114) can include a tank (114-1) to store fluid nitrogen, an evaporator (114-2) to convert the fluid nitrogen into gaseous nitrogen, and an inlet (114-3) to supply the gaseous nitrogen to the air-tight chamber (110). The evaporator (114-2) can be connected to the tank (114-1) and the inlet (114-3) to ensure a continuous and regulated flow of gaseous nitrogen. The nitrogen supply can help prevent oxidation and reduce the risk of hazardous reactions during battery shredding.

[0041] In an embodiment, a hammer mill (116) can be connected to the shredder (112) and can crush the shredded pieces into fine particles. The hammer mill (116) can include rotating hammers or impact surfaces designed to break down battery materials into smaller, manageable particles. The crushed particles can be transferred to a heating chamber (118) connected to the hammer mill (116). The heating chamber (118) can apply heating to evaporate the electrolyte from the fine particles, thereby obtaining an electrolyte-free material. The heating chamber (118) can be a closed chamber, ensuring that electrolyte vapors are contained and properly managed. The heating can be applied through thermic fluid heating, electric heating, microwave heating, infrared (IR) heating, and hot air circulation (convection heating).

[0042] Further, a rotary airlock valve (120) can be connected to the heating chamber (118) and can regulate the transportation of the electrolyte-free material while maintaining the inert environment. The rotary airlock valve (120) can prevent atmospheric air from entering the system (102), thereby ensuring continuous processing without exposure to external contaminants. The electrolyte-free material can be transferred from the rotary airlock valve (120) to a vibrating screen (122). The vibrating screen (122) can be mechanically connected to the rotary airlock valve (120) and can separate the electrolyte-free material from residual material. The vibrating screen (122) can include multiple mesh layers or graded sieves to facilitate the classification of materials based on size and composition, ensuring that only purified and processed materials move forward for collection or further refining.

[0043] In such embodiment, the system (102) can also include an electrolyte suction apparatus (124) positioned at the top side of the heating chamber (118). The electrolyte suction apparatus (124) can extract the evaporated electrolyte vapors from the heating chamber (118), preventing the accumulation of hazardous fumes and ensuring a safer processing environment. The extracted vapors can be directed to a collection or neutralization system to manage the electrolyte safely.

[0044] In such embodiment, the system (102) can be designed for efficient and safe processing of batteries under an inert environment, ensuring minimal environmental impact and improved recovery of materials. The structural configuration and functional integration of the components can provide a controlled and automated operation for handling, shredding, and refining battery materials while maintaining safety and efficiency.

[0045] In such embodiment, the nitrogen assembly (114) can include a tank (114-1) designed to store fluid nitrogen under controlled pressure and temperature conditions. The tank (114-1) can be structured to ensure safe storage and regulated release of fluid nitrogen as required. The nitrogen assembly (114) can further include an evaporator (114-2) connected to the tank (114-1) to facilitate the conversion of fluid nitrogen into gaseous nitrogen. The evaporator (114-2) can function using heat exchange mechanisms, which allow efficient and continuous conversion while maintaining a stable supply of gaseous nitrogen. The nitrogen assembly (114) can also include an inlet (114-3) connected to the evaporator (114-2) and the air-tight chamber (110) to supply the gaseous nitrogen at a controlled rate. The inlet (114-3) can be designed with flow control valves and sensors to regulate and monitor the nitrogen supply, ensuring the maintenance of an inert atmosphere inside the air-tight chamber (110) during battery processing.

[0046] In such embodiment, the system (102) can include a shredder (112) configured to reduce batteries into smaller pieces for further processing. The shredder (112) can be positioned beneath the air-tight chamber (110) to receive batteries in a controlled manner. The shredder (112) can include a plurality of shafts (112-1) equipped with cutting blades to perform efficient shredding of the batteries. The shafts (112-1) can be configured in an intermeshing arrangement to enhance the shredding efficiency and prevent material buildup. The cutting blades can be manufactured from high-strength materials such as hardened steel to withstand mechanical stress and prolonged usage. The shredder (112) can be driven by an electric or hydraulic motor, allowing for adjustable speed and torque control based on the type and size of batteries being processed. The design of the shredder (112) can ensure uniform size reduction, facilitating downstream material handling and processing.

[0047] In another embodiment, the system (102) can include a heating chamber (118) connected to the hammer mill (116) to apply heat treatment for electrolyte removal from the fine battery particles. The heating chamber (118) can be a closed structure designed to contain and regulate heat application, ensuring efficient processing while preventing external contamination. The heating can be applied through one or more means, including thermic fluid heating, electric heating, microwave heating, infrared (IR) heating, and hot air circulation (convection heating). The selection of a suitable heating method can depend on factors such as processing speed, energy efficiency, and material compatibility.

[0048] In yet another embodiment, thermic fluid heating can involve circulating heated fluid through an external heat exchanger to maintain a consistent processing temperature. Electric heating can include resistive heating elements embedded within the chamber walls to generate uniform heat distribution. Microwave heating can generate heat using microwave radiation, ensuring rapid and uniform heating. Infrared heating can involve the application of infrared radiation to facilitate surface heating. Hot air circulation can involve forced convection of heated air within the chamber (118) to ensure thorough drying and electrolyte evaporation. The heating chamber (118) can be equipped with temperature control mechanisms, safety sensors, and exhaust outlets to manage thermal conditions and prevent overheating.

[0049] In an embodiment, the air-tight chamber (110) can include the first valve (110-1) positioned at a top side to allow controlled entry of batteries and the second valve (110-2) positioned at a bottom side to regulate the transfer of batteries to a shredder (112). The first valve (110-1) can be an electronically controlled or pneumatically operated valve, enabling precise opening and closing to ensure a sequential and safe transfer of batteries. The second valve (110-2) can also be electronically or pneumatically actuated, designed to release batteries into the shredder (112) while maintaining the integrity of the inert environment within the air-tight chamber (110). The placement of the first valve (110-1) and the second valve (110-2) can facilitate a controlled material flow, reducing the risk of exposure to hazardous substances present within the batteries.

[0050] In another embodiment, the system (102) can include an electrolyte suction apparatus (124) positioned at the top side of the heating chamber (118). The electrolyte suction apparatus (124) can be designed to extract evaporated electrolyte vapors generated during the heating process in the heating chamber (118). The electrolyte suction apparatus (124) can include a vacuum-based extraction system or a gas collection system, ensuring that evaporated electrolyte vapors are efficiently removed from the heating chamber (118). The extracted vapors can be directed to a neutralization or condensation unit for safe handling and disposal. The positioning of the electrolyte suction apparatus (124) at the top side of the heating chamber (118) can facilitate the efficient capture of rising electrolyte vapors, preventing accumulation within the chamber and ensuring a controlled processing environment.

[0051] In yet another embodiment, the system (102) can include a mechanism for handling residual material after the separation of electrolyte-free material. The residual material can be selected from any or a combination of plastic casing or housing, binder materials, non-metallic impurities, and unusable fine particles. The residual material can be collected through a vibrating screen (122) connected to a rotary airlock valve (120), ensuring the separation of recoverable material from non-reusable components. The plastic casing or housing can refer to the external protective layers of the batteries that remain after processing. The binder materials can include adhesives or polymeric substances used in battery construction. Non-metallic impurities can include ceramic separators or insulation materials, while unusable fine particles can consist of fragmented debris that cannot be further processed. The collection and disposal of the residual material can be managed through a dedicated waste management system to ensure environmental compliance and safe disposal practices.

[0052] The system (102) can be structured to provide a continuous, safe, and efficient method for battery recycling, ensuring that materials are processed with minimal exposure to hazardous substances. The positioning of critical components, such as the first valve (110-1), the second valve (110-2), and the electrolyte suction apparatus (124), can enhance operational efficiency while maintaining a controlled and inert environment within the processing chambers.

[0053] FIG. 2 illustrates an exemplary representation of a method (200) of shredding and processing batteries under an inert environment, in accordance with an exemplary embodiment of the present disclosure.

[0054] Referring to FIG. 2, in an embodiment, the method (200) of shredding and processing batteries under the inert environment can include multiple steps performed using the various components illustrated hereinafter.

[0055] At block 202, the method (200) can include a process for shredding and processing batteries under an inert environment to ensure safe handling and recovery of materials. The method (200) can begin with a step of receiving batteries to be recycled by the first hopper (104). The first hopper (104) can be implemented to hold and regulate the flow of batteries before further processing. The first hopper (104) can be constructed with durable materials to withstand mechanical stress and prevent damage due to battery weight and chemical composition.

[0056] At block 204, the method (200) can include the step of transporting the batteries from the first hopper (104) to the second hopper (108) using the conveyor belt (106). The conveyor belt (106) can facilitate the movement of batteries in a controlled manner, ensuring an even and regulated flow. The conveyor belt (106) can be made of materials resistant to chemical corrosion and mechanical wear, allowing safe transportation of batteries of varying sizes and compositions. The second hopper (108) can be positioned at an elevated level to ensure the efficient transfer of batteries into the next stage of processing.

[0057] At block 206, the method (200) can include the step of receiving batteries by the air-tight chamber (110) through the second hopper (108). The air-tight chamber (110) can be structured to maintain a controlled environment, preventing the exposure of batteries to atmospheric oxygen. The air-tight chamber (110) can include the first valve (110-1) and the second valve (110-2).

[0058] At block 208, the first valve (110-1) can be positioned at a top side of the air-tight chamber (110) and can allow controlled entry of batteries when open.

[0059] At block 210, the second valve (110-2) can be positioned at a bottom side of the air-tight chamber (110) and can facilitate the transfer of batteries to a shredder (112) when open. The first valve (110-1) and the second valve (110-2) can be electronically controlled to synchronize with the battery feeding cycle, ensuring minimal disruption to the inert environment. The method (200) can further include shredding the batteries into pieces using a shredder (112) positioned beneath the air-tight chamber (110). The shredder (112) can include multiple shafts with cutting blades implemented to break down the battery casings and internal components. The cutting blades can be made of hardened materials capable of withstanding the impact and stress of battery shredding. The shredder (112) can be powered by an electric or hydraulic motor, allowing controlled speed variations based on battery type and composition. The shredding process can help expose the internal materials for further separation and processing.

[0060] At block 212, the method (200) can include the step of supplying gaseous nitrogen into the air-tight chamber (110) through a nitrogen assembly (114) to create and maintain an inert environment. The nitrogen assembly (114) can include a tank (114-1) for storing fluid nitrogen, an evaporator (114-2) to convert fluid nitrogen into gaseous nitrogen, and an inlet (114-3) to regulate nitrogen flow into the air-tight chamber (110). The supply of gaseous nitrogen can help prevent oxidation and hazardous reactions during battery shredding and subsequent processing.

[0061] At block 214, the method (200) can include the step of crushing the shredded pieces into fine particles using a hammer mill (116) connected to the shredder (112). The hammer mill (116) can utilize high-impact rotating hammers to further reduce the particle size of the shredded battery materials. The fine particles can include active battery materials, casing fragments, and other recoverable or residual components. The hammer mill (116) can be designed to withstand the abrasive nature of the battery components and operate under controlled conditions to minimize dust formation.

[0062] At block 216, the method (200) can include the step of applying heating to the fine particles in a heating chamber (118) connected to the hammer mill (116) to evaporate the electrolyte, thereby obtaining electrolyte-free material. The heating chamber (118) can be a closed system to ensure safe containment of electrolyte vapors. The heating can be applied through various means, including thermic fluid heating, electric heating, , infrared (IR) heating, or hot air circulation (convection heating). The heating chamber (118) can be equipped with sensors and control mechanisms to regulate temperature levels and prevent overheating, ensuring efficient electrolyte removal.

[0063] At block 218, the method (200) can include the step of regulating the transportation of electrolyte-free material using a rotary airlock valve (RAV) (120) connected to the heating chamber (118) while maintaining the inert environment. The rotary airlock valve (120) can function as a controlled passageway, preventing atmospheric exposure while facilitating the movement of processed material. The rotary airlock valve (120) can be designed to handle fine particles and prevent clogging during operation.

[0064] At block 220, the method (200) can include separating the electrolyte-free material from residual material using a vibrating screen (122) mechanically connected to the rotary airlock valve (120). The vibrating screen (122) can function by utilizing oscillatory motion to classify and separate usable materials from residual components. The residual material can include plastic casing, binder materials, non-metallic impurities, and unusable fine particles. The vibrating screen (122) can be designed to operate under continuous conditions, ensuring efficient separation and collection of materials for further recovery or disposal.

[0065] In such embodiment, the method (200) can be structured to enable safe, efficient, and controlled processing of batteries under an inert environment. The systematic sequence of receiving, shredding, crushing, heating, and separating battery materials can facilitate material recovery while minimizing environmental impact and exposure to hazardous substances. The controlled operations of the air-tight chamber (110), nitrogen assembly (114), heating chamber (118), rotary airlock valve (120), and vibrating screen (122) can ensure smooth and continuous battery processing while maintaining safety and efficiency. Through the sequence of operations, the system (102) can effectively process used batteries under the inert environment, ensuring safe handling, material recovery, and waste separation.

[0066] FIG. 3 illustrates an exemplary representation of process layout (300) illustrating the overall working of the proposed system (102), in accordance with an exemplary embodiment of the present disclosure.

[0067] Referring to FIG. 3, the process layout (300) illustrates the method (200) for shredding and processing batteries under an inert environment. The method (200) ensures the safe handling and recovery of materials from used batteries while preventing unwanted reactions. In the initial step, batteries are received (202) by a first feed hopper (104), which serves as the entry point for used batteries into the system at step 302 i.e. 'battery feed'. The batteries are then transported (204) through the cover belt (106), which is covered with a protective cover belt (106) to minimize exposure to external conditions. The conveyor belt (106) directs the batteries toward a second feed hopper (108) at step 304.

[0068] Once the batteries reach the second feed hopper (108), they are received (206) by an air-tight chamber (110), which is equipped with a first flap valve (110-1) and a second flap valve (110-2). The first flap valve (110-1) allows (208) the entry of batteries into the air-tight chamber (110) when open. After the batteries enter, the first flap valve (110-1) closes to maintain the inert environment. The second flap valve (110-2) then transfers (210) the batteries to a shredder (112) positioned beneath the air-tight chamber (110).

[0069] Further, the nitrogen assembly (114) is provided to supply (212) gaseous nitrogen into the air-tight chamber (110) to create and maintain an inert environment. The nitrogen assembly (114) includes a liquid nitrogen tank (114-1), an evaporator (114-2), and a nitrogen inlet (114-3). The evaporator (114-2) converts fluid nitrogen (306) into gaseous nitrogen, which is introduced into the air-tight chamber (110) through the nitrogen inlet (114-3).

[0070] Inside the shredder (112), the batteries are shredded into smaller pieces. These shredded pieces are further crushed (214) by a hammer mill (116), which is mechanically connected to the shredder (112), to reduce them into fine particles. The fine particles are then transported to a heating chamber (118), where heat is applied (216) to evaporate electrolyte (312) from the fine particles, obtaining an electrolyte-free material. The heating chamber (118) may utilize thermic fluid heating, as indicated by the thermal fluid outlet (308).

[0071] Furthermore, the electrolyte-free material is transferred from the heating chamber (118) through a rotary airlock valve (RAV) (120), which regulates (218) the transportation of material while maintaining the inert atmosphere. The rotary airlock valve (120) ensures controlled material flow while preventing air ingress.

[0072] The processed material is then directed to a vibrating screen (122), which performs separation (220) of the electrolyte (312) and electrolyte-free material from residual components at step 310. The vibrating screen (122) sorts the material, collecting black mass (314) as a recoverable component while allowing fine particles (316) to be separated effectively. The process layout (300) provides a detailed depiction of each step in the method (200), ensuring efficient processing of batteries under an inert environment to facilitate material recovery.

[0073] What are described above are merely preferred embodiments of the present disclosure, and are not to limit the present disclosure. Any modification, equivalent replacement, and improvement within the principle of the present disclosure should be included in the protection scope of the present disclosure.ADVANTAGES OF THE DISCLOSURE

[0074] The proposed disclosure provides a system and a method of shredding and processing batteries under an inert environment.

[0075] The proposed disclosure provides a system that significantly reduces the risk of fires and chemical reactions during the shredding and processing of lithium-ion batteries by operating under the inert atmosphere using nitrogen gas.

[0076] The proposed disclosure provides a system that eliminates the need for pre-discharge of batteries, which is a time-consuming and costly step in conventional recycling methods.

[0077] The proposed disclosure provides a system that maximizes the recovery of valuable materials such as lithium, cobalt, nickel, and graphite which supports resource sustainability and reduces the dependency on raw material extraction.

[0078] The proposed disclosure provides a system and a method that integrates mechanical and thermal processes within the system simplifies the recycling workflow, enhances throughput, and improves overall operational efficiency.

[0079] The proposed disclosure provides a system and a method that minimizes the environmental impact of battery recycling by preventing the release of hazardous substances and promoting the reuse of recovered materials.

[0080] The proposed disclosure provides a system and a method that can be adapted to handle various types of lithium-ion batteries, making it versatile and applicable to a wide range of recycling scenarios.

[0081] The proposed disclosure provides a system and a method that eeliminates saline discharging water thus eliminating requirement of Effluent Treatment Plant (ETP), which reduces time, energy and thus becomes cost effective.

Claims

1. A system (102) to shred and process batteries under an inert environment, the system (102) comprising: a first hopper (104) to receive batteries to be recycled; a conveyor belt (106) operatively coupled to the first hopper (104) to transport the batteries to a second hopper (108); an air-tight chamber (110) receives the batteries through the second hopper (108), wherein the air-tight chamber (110) comprising: a first valve (110-1) positioned to allow entry of the batteries when open; a second valve (110-2) positioned to transfer the batteries to a shredder (112) when open, wherein the shredder (112) is positioned beneath of the air-tight chamber (110) to shred the batteries into pieces; a nitrogen assembly (114) to supply gaseous nitrogen into the air-tight chamber (110) to create and maintain an inert environment; a hammer mill (116) mechanically coupled to the shredder (112) to crush the shredded pieces into fine particles; a heating chamber (118) coupled to the hammer mill (116) to apply heating to evaporate electrolyte from the fine particles, to obtain an electrolyte-free material; a rotary airlock valve (RAV) (120) coupled to the heating chamber (118) to regulate transportation of the electrolyte-free material while maintaining the inert environment; and a vibrating screen (122) mechanically coupled to the RAV (120) to separate the electrolyte-free material from residual material.

2. The system (102) as claimed in claim 1, wherein the nitrogen assembly (114) comprises a tank (114-1) to store fluid nitrogen, an evaporator (114-2) to convert the fluid nitrogen into gaseous nitrogen, and an inlet (114-3) to supply the gaseous nitrogen to the air-tight chamber (110) to maintain the inert environment, wherein the evaporator (114-2) is coupled to the tank (114-1) and the inlet (114-3).

3. The system (102) as claimed in claim 1, wherein the shredder (112) comprises a plurality of shafts (112-1) having cutting blades to shred the battery.

4. The system (102) as claimed in claim 1, wherein the heating chamber (118) is a closed chamber, and the heating is applied through one or more means selected from any or a combination of thermic fluid heating, electric heating, microwave heating, infrared (IR) heating, and hot air circulation (convection heating).

5. The system (102) as claimed in claim 1, wherein the first valve (110-1) is positioned at a top side of the air-tight chamber (110) and the second valve (110-2) is positioned at a bottom side of the air-tight chamber (110).

6. The system (102) as claimed in claim 1, wherein the system (102) further comprises an electrolyte suction apparatus (124) positioned at the top side of the heating chamber (110) to extract the evaporated electrolyte vapors.

7. The system (102) as claimed in claim 1, wherein the residual material is selected from any or a combination of plastic casing or housing, binder materials, non-metallic impurities, and unusable fine particles.

8. A method (200) of shredding and processing batteries under an inert environment, the method (200) comprising: receiving (202), by a first hopper (104), batteries to be recycled; transporting (204), by a conveyor belt (106), the batteries to a second hopper (108), wherein the conveyor belt (106) operatively coupled to the first hopper (104); receiving (206), by an air-tight chamber (110), the batteries through the second hopper (108), wherein the air-tight chamber (110) comprises a first valve (110-1) and a second valve (110-2): allowing (208), by the first valve (110-1), entry of the batteries when open; transferring (210), by a second valve (110-2 the batteries to a shredder (112) when open, wherein the shredder (112) is positioned beneath of the air-tight chamber (110) to shred the batteries into pieces; supplying (212), by a nitrogen assembly (114), gaseous nitrogen into the air-tight chamber (110) to create and maintain an inert environment; crushing (214), by a hammer mill (116), the shredded pieces into fine particles, wherein the hammer mill (116) is mechanically coupled to the shredder (112); applying (216), by a heating chamber (118), heating to evaporate electrolyte from the fine particles, to obtain an electrolyte-free material, wherein the heating chamber (118) is coupled to the hammer mill (116); regulating (218), by a rotary airlock valve (RAV) (120), transportation of the electrolyte-free material while maintaining the inert environment, wherein the rotary airlock valve (RAV) (120) is coupled to the heating chamber (118); and separating (220), by a vibrating screen (122) the electrolyte-free material from residual material, wherein the vibrating screen (122) is mechanically coupled to the RAV (120).

9. The method (200) as claimed in claim 8, wherein the nitrogen assembly (114) comprises a tank (114-1) to store fluid nitrogen, an evaporator (114-2) to convert the fluid nitrogen into gaseous nitrogen, and an inlet (114-3) to supply the gaseous nitrogen to the air-tight chamber (110) to maintain the inert environment, wherein the evaporator (114-2) is coupled to the tank (114-1) and the inlet (114-3).

10. The method (200) as claimed in claim 8, wherein the method (200) further comprises a step of extracting, by an electrolyte suction apparatus (124), the evaporated electrolyte vapors, wherein the electrolyte suction apparatus (124) is positioned at the top side of the heating chamber (110).