Systems and methods for separating active material from lithium ion batteries

Abstract

Various embodiments of the present invention provide a system and method for separating active materials from lithium-ion batteries. The system includes a fluid chamber, a crusher-grinding device, a material inlet mechanism, a gas outlet mechanism, and a material outlet mechanism. After multiple processes, high density materials such as aluminum, copper, iron, etc. are separated by size classification. When the liquid suspension reaches a stable state, the water on top and the powder that has settled at the bottom are collected. The powder separated from the suspension is considered as a black mass, which contains the active materials from the lithium-ion batteries. The agitator tank breaks down the materials introduced therein into smaller sizes proportional to their brittleness. The materials are then processed by density separation, followed by wet side classification to separate the metals and active materials, followed by dehydration.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Embodiments of the present specification claim priority to Indian provisional patent application filed on February 3, 2022, bearing number 202211005730 and entitled "SYSTEM AND METHOD FOR SEPARATION OF ACTIVE MATERIAL FROM LITHIUM-ION BATTERIES," the contents of which are incorporated herein by reference in their entirety.

[0002]

[0002] The present invention relates generally to lithium ion batteries, in particular to systems and methods for enabling safe disposal of lithium ion batteries, and more particularly to systems and methods for separating metals and active materials from lithium ion batteries. [Background technology]

[0003]

[0003] Safe disposal of used lithium ion batteries has become very important in recent years due to the large-scale production of lithium ion batteries to power various devices and appliances. Currently, safe disposal of used lithium ion batteries is not without challenges, mainly due to the presence of active materials, stored energy, and other hazardous components in used batteries.

[0004]

[0004] In current methods, to separate the active material from lithium-ion batteries, a process of grinding is carried out, followed by air classification and sieving. This process is carried out either in a neutral or inert atmosphere of nitrogen or argon, or under cryogenic conditions to prevent fire. Some current methods also involve spraying water with additives during the grinding process, which mitigates some of the problems encountered, but does not completely solve them. Also, the processes typically used do not directly produce high purity materials.

[0005]

[0005] Therefore, there is a need for an efficient and safe system for separating active materials from lithium ion batteries.

[0006]

[0006] The above mentioned shortcomings, drawbacks, and problems are addressed herein, which will be understood by reading and studying the following detailed description. Summary of the Invention [Problem to be solved by the invention]

[0007] A primary object of the present invention is to provide a system and method for the safe separation of active material from a lithium ion battery.

[0008] Another object of the present invention is to provide an efficient and safe system for separating active material from a lithium ion battery.

[0009] It is yet another object of the present invention to provide a self-contained crushing system that opens a sealed system and crushes the batteries in hot water or other fluids in order to reduce the size of the components.

[0010]

[0010] It is yet another object of the present invention to provide an underwater stirring process and subsequent use of the stirring effect and active separation process, as well as classification using particle-particle grinding and wet sieving to separate the components of the battery.

[0011] It is yet another object of the present invention to provide a system configured to use thermal shock to separate black masses that are attached to a foil using PVDF.

[0012] These and other objects and advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. [Means for solving the problem]

[0013] Various embodiments of the present invention provide a system and method for separating active materials from lithium ion batteries. The system includes a fluid chamber, a crusher-grinding device, a material inlet mechanism, a gas outlet mechanism, and a material outlet mechanism.

[0014] According to one embodiment of the present invention, a system for efficient and safe separation of active material from lithium-ion batteries is provided. The batteries are first washed with water to remove dirt and then crushed in a crusher. The crusher is constantly fed with scrape batteries. The crusher is submerged in cold demineralized water or other fluid inside a sealed tank so that the crushing action always occurs in the water or fluid and the exhaust gases are trapped. The batteries are crushed by blades that break down the complex structures into smaller pieces and any remaining energy stored in the batteries creates localized heat areas that separate the active material from the foil. Some electrolyte solvents used in batteries have low boiling points and boil due to localized heating during the electrolyte reaction with water. Other electrolyte solvents used in batteries dissolve in the fluid during the electrolyte reaction with water. Volatile organics such as exhaust steam and exhaust gases are cleaned, compressed, cooled and stored in a container.

[0015] According to one embodiment of the present invention, the crushed or ground material is subjected to an agitated environment such as an agitator or agitator. The agitator is run at preselected processing conditions (such as run time, solid / liquid ratio, and RPM). After agitation, the tank reaches a partial steady state, which is why three distinct components are formed and collected: low density material at the top, suspension, and settled high density material at the bottom. High density materials such as aluminum, copper, and iron are separated by size classification. Once the liquid suspension reaches a steady state, the water on top and the settled powder at the bottom are collected. The powder separated from the suspension is considered as black mass, and the liquid is vaporized to collect the electrolyte.

[0016]

[0016] According to one embodiment of the invention, the stirred tank is configured to break down a plurality of materials introduced therein into smaller particles in proportion to the brittleness of the materials. The stirred tank is submerged in a fluid environment so that the ductile materials remain as larger particles while the plurality of other materials are pulverized and form a suspension in the fluid. The suspension is first removed and processed through a screen, and then the larger particles are separated through density separation. The suspension and larger particles are then processed through a wet size classification system to separate materials of different sizes, followed by dewatering.

[0017]

[0017] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments and numerous specific details thereof, is given by way of illustration and not limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

[0018] Other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings. [Brief description of the drawings]

[0019] [Figure 1] FIG. 1 illustrates a system for separating active material from a lithium-ion battery according to one embodiment of the present invention. [Diagram 2]

[0020] FIG. 1 illustrates an exemplary system for separating active material from a lithium-ion battery, according to one embodiment of the present invention. [Diagram 3]

[0021] FIG. 1 illustrates a method for separating active material from a lithium-ion battery according to one embodiment of the present invention. [Figure 4]

[0022] FIG. 2 illustrates an SEM image of a lithium ion battery after crushing, according to an exemplary embodiment of the present invention. [Diagram 5]

[0023] FIG. 1 illustrates SEM images of different components after size and density separation of crushed lithium ion batteries according to one exemplary embodiment of the present invention. [Figure 6]

[0024] FIG. 1 illustrates XRD result readouts and charts of different components of crushed lithium ion batteries after separation by size and density according to one exemplary embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020]

[0025] Specific features of the invention may be shown in some drawings and not in others. This is done for convenience only, since each feature may be combined with any or all of the other features in accordance with the invention.

[0021]

[0026] In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration specific embodiments which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments, it being understood that other modifications may be made without departing from the scope of the embodiments. Thus, the following detailed description should not be taken in a limiting sense.

[0022]

[0027] Various embodiments of the present invention provide a system and method for separating metals and active materials from lithium ion batteries. The system includes a fluid chamber, a crusher-grinding device, a material inlet mechanism, a gas outlet mechanism, and a material outlet mechanism.

[0023]

[0028] According to one embodiment of the invention, the fluid chamber further comprises a washing mechanism designed to remove fluids such as water and dirt introduced into the fluid chamber. The crusher-crusher device is contained in the fluid chamber and submerged therein, so that all operations of the crusher-crusher device are effected in a fluid environment such that the produced exhaust gas is trapped. The material inlet mechanism is designed to be further connected to the agitator vessel, which is contained in the fluid chamber and designed to operate in a fluid environment and to allow wet screening. The gas outlet mechanism is designed to pass the produced exhaust gas through a scrubber, followed by a compressor and a cooler, so that the gas is compressed, liquefied, cooled and stored in a container. The material outlet mechanism is designed to remove the separated material.

[0024]

[0029] According to one embodiment of the invention, the temperature of the fluid in the fluid chamber is maintained below the boiling point of the battery's electrolyte solution through active cooling.

[0025]

[0030] According to one embodiment of the invention, the stirred tank is designed to operate at preset conditions. The stirred tank is configured to break down the materials introduced therein into smaller pieces proportional to the brittleness of the materials. The stirred tank is submerged in a fluid environment, so that the ductile materials remain as larger particles while the other materials are pulverized and form a suspension in the fluid. The suspension is first removed and processed through a screen, and then the larger particles are separated through density separation. The suspension and the larger particles are then processed through a wet size classification system to separate materials of different sizes, followed by dewatering.

[0026]

[0031] According to one embodiment of the present invention, the stirred tank is maintained in a weakly acidic condition by introducing additional fluid into the fluid environment. Once the process is completed, the fluid used in the process is treated to extract the dissolved material. When the purity of the size components of the material is not as pure as the pre-set specifications, the material is subjected to thermal shock in hot and cold water and reprocessed in the stirred tank.

[0027]

[0032] According to one embodiment of the present invention, a method for separating active materials from lithium-ion batteries is provided, which includes the steps of washing the lithium-ion batteries in a fluid chamber to remove dirt and discharge, crushing the batteries in a crusher-grinding device that is submerged in a fluid environment in the fluid chamber, removing gaseous exhaust through a gas outlet mechanism, transferring the crushed material to an agitator tank that operates in a fluid environment and is designed to allow wet sieving, separating the crushed material into fine and coarse particles by breaking them down into smaller sizes proportional to the brittleness of the material, the coarse material being a ductile material that remains as larger particles, and the fine material being pulverized to form a suspension in a fluid, subjecting the material to coarse differential and density separation, classifying the fine and coarse material by size through sieving, dehydrating the separated material by removing water and moisture through a suitable setting, and removing the separated material through a material outlet mechanism.

[0028]

[0033] According to one embodiment of the present invention, a system for efficient and safe separation of active materials from lithium-ion batteries is provided. The batteries are first washed with water to remove dirt and then crushed in a crusher. The crusher is constantly fed with scrap batteries. The crusher is submerged in distilled hot water or other fluid inside a sealed tank so that the crushing action always occurs in water or fluid and exhaust gases are trapped. The batteries are crushed by blades that break down the complex structures into smaller pieces, and any remaining energy stored in the batteries creates localized heat areas that separate the active materials from the foil. The electrolyte used in the batteries has a low boiling point and boils during the electrolyte reacts with water. The electrolyte solvent used in the batteries dissolves in the fluid during the electrolyte reacts with water. Volatile organics such as exhaust steam and exhaust gases are compressed, cooled, and stored in a container.

[0029]

[0034] According to one embodiment of the present invention, the crushed or pulverized material is subjected to an agitated environment, such as an agitator or agitator. The agitator is run at preselected processing conditions (such as runtime, solid / liquid ratio, and RPM). After agitation, the tank reaches a partial steady state, which is why three different components are formed and collected, specifically, the low density material at the top, the suspension, and the settled high density material at the bottom. The high density materials, such as aluminum, copper, and iron, are separated by size classification. Once the liquid suspension reaches a steady state, the water on top and the settled powder at the bottom are collected. The powder separated from the suspension is considered as black mass, and the liquid is evaporated to collect the electrolyte.

[0030]

[0035] According to one embodiment of the invention, the stirred tank is configured to break down a plurality of materials introduced therein into smaller particles proportional to the brittleness of the materials. The stirred tank is submerged in a fluid environment, so that the ductile materials remain as larger particles while the plurality of other materials are pulverized and form a suspension in the fluid. The suspension is first removed and processed through a screen, and then the larger particles are separated through density separation. The suspension and the larger particles are then processed through a wet size classification system to separate materials of different sizes, followed by dewatering.

[0031]

[0036] According to one embodiment, an exemplary system, method, and results are provided for efficient and safe separation of active materials from lithium-ion batteries. A 200 kg batch of charged batteries was crushed in demineralized water for 1 hour to a particle size of about 7.5 mm. FIG. 4 illustrates an SEM image after crushing, and the cracks in the SEM image show that underwater crushing enabled safe crushing by creating localized heat areas. After crushing, the material was stirred at 600 rpm and 1 / 5 solid to liquid ratio with 5 LPM carbon dioxide flow rate for 45 minutes. And subsequently, the material was subjected to size and density classification in demineralized water. The sieve size was uniformly distributed between 44 microns and 5 mm. FIG. 5 illustrates an SEM image of different components after size and density separation, and FIG. 6 illustrates the readout and chart of XRD results. Both figures illustrate good separation of different components of the material inside the lithium-ion battery, as well as separation of metal and black chunks.

[0032]

[0037] 1 illustrates a system for separating active materials from a lithium ion battery. The system includes a fluid chamber 101, a crusher-grinding device 102, a material inlet mechanism 103, a gas outlet mechanism 104, and a material outlet mechanism 105.

[0033]

[0038] FIG. 2 illustrates an exemplary separation module provided in a system for separating active materials from a lithium ion battery.

[0034]

[0039] 3 illustrates a method for separating active material from lithium ion batteries. The method includes the steps of washing the lithium ion batteries in a fluid chamber to remove dirt (301), crushing the batteries in a crusher-grinding device that is submerged in a fluid environment in the fluid chamber (302), removing gaseous exhaust through a gas outlet mechanism (303), transferring the crushed material to an agitator vessel (304), which operates in a fluid environment and is designed to allow wet sieving, and breaking down the crushed material into smaller sizes proportional to the friability of the crushed material. The process thus includes steps of separating the material into fine and coarse particles (305), where the coarse material is a ductile material that remains in larger particles and the fine material is powdered to form a suspension in a fluid (305), subjecting the material to coarse differentiation and density separation (306), classifying the fine and coarse material by size by sieving (307), dewatering the separated material by removing water and moisture through a suitable set up (308), and removing the separated material through a material outlet mechanism (309).

[0035]

[0040] Figure 4 illustrates an SEM image of a lithium-ion battery after fracturing. The cracks in the SEM image indicate that underwater fracturing enabled safe fracturing by creating localized thermal regions.

[0036]

[0041] Figure 5 illustrates SEM images of different components after size and density separation of crushed lithium ion batteries. 5a and 5b illustrate large size particles such as copper, aluminum, and lithium metal oxide content. 5c and 5d illustrate medium size particles such as lithium metal oxide, graphite, and some metal content. 5e and 5f illustrate small size particles such as graphite and some lithium metal oxide content.

[0037]

[0042] Figure 6 illustrates the XRD result readout and chart of different components of the crushed lithium ion battery after separation by size and density. This figure illustrates good separation of different components of the inner material of the lithium ion battery as well as separation of metal and black chunks.

[0038]

[0043] Although the embodiments herein are described with reference to various specific embodiments, it will be apparent to those skilled in the art that they may practice the embodiments herein with modifications.

[0039] Effect of the Invention

[0044] Various embodiments of the present invention provide systems and methods for separating active materials from lithium ion batteries. The invention eliminates the need to discharge the battery and the requirement for additional precautions to avoid hazardous batteries. The invention does not require a neutral or cryogenic environment and improves the efficiency of the separation process by minimizing contamination, along with providing sorting of the separated components with higher purity and yield compared to conventional methods currently used.

[0040]

[0045] The foregoing description of the specific embodiments has so fully revealed the general nature of the embodiments herein, which can be easily modified and / or adapted for various applications, such as specific embodiments, by applying current knowledge, without departing from the generic concept, and therefore such adaptations and modifications are intended to be understood within the meaning and range of equivalents of the disclosed embodiments. It should be understood that the expressions and terms used herein are for the purpose of description, not limitation. Thus, although the embodiments herein have been described in terms of preferred embodiments, those skilled in the art shall recognize that the embodiments herein can be practiced with modifications. However, all such modifications are deemed to be within the scope of the claims.

Claims

1. 1. A system for separating active material from a lithium ion battery, comprising: a fluid chamber, the fluid chamber further comprising a cleaning mechanism designed to remove fluid, such as water, and contaminants introduced into the fluid chamber; a crusher-crusher apparatus, the crusher-crusher apparatus being contained within and submerged in the fluid chamber, so that all operations of the crusher-crusher apparatus are effected within a fluid environment such that exhaust gases produced are confined; a material inlet mechanism, the material inlet mechanism being designed to be further connected to an agitated vessel, the agitated vessel being contained within the fluid chamber, the agitated vessel being designed to operate within a fluid environment and to enable wet sieving; a gas outlet mechanism designed to pass the produced exhaust gas through a scrubber, followed by a compressor and a cooler, so that the gas is compressed, liquefied, cooled and stored in a container; a material exit mechanism designed to remove the separated material; and A system comprising:

2. 10. The system of claim 1, wherein the temperature of the fluid in the fluid chamber is maintained below the boiling point of the battery's electrolyte solution through active cooling.

3. 2. The system of claim 1, wherein the agitated vessel is designed to operate at preset conditions, the agitated vessel is configured to break down a plurality of materials introduced therein into smaller sizes proportional to the brittleness of the materials, and wherein the agitated vessel is immersed in the fluid environment so that ductile materials remain as larger particles while a plurality of other materials are powdered and form a suspension in the fluid, the suspension is first removed and processed through a screen, then the larger particles are separated by density separation, and the suspension and larger particles are processed through a wet size classification system to separate materials of different sizes, followed by dewatering.

4. 4. The system of claim 3, wherein the stirred tank is maintained at a weakly acidic condition by introducing additional fluid into the fluid environment, and once the process is completed, the fluid used in the process is treated to extract dissolved materials, and when the purity of the size components of the materials is not as pure as a pre-set specification, the materials are subjected to thermal shock in hot and cold water and reprocessed in the stirred tank.

5. 1. A method for separating active material from a lithium ion battery, comprising: washing the lithium ion battery in a fluid chamber to remove contaminants; crushing the batteries in a crusher-crusher device submerged in a fluid environment within the fluid chamber; removing the gaseous exhaust through a gas outlet arrangement; transferring the crushed material to an agitated vessel, the agitated vessel being designed to operate in a fluid environment and to allow for wet sieving; Separating the crushed material into fine and coarse particles by breaking it down into smaller sizes proportional to the brittleness of the crushed material, the coarse material being a ductile material which remains in larger particles, and the fine material being pulverized to form a suspension in the fluid; subjecting the material to crude differential fractionation and density separation; classifying the fine and coarse material by size by sieving; dehydrating the separated material by removing water and moisture through a suitable set up; removing said separated material through a material outlet mechanism; A method comprising:

6. 6. The method of claim 5, wherein the fluid chamber further comprises a fluid such as water or propanol, and the crusher-grinding apparatus is contained within and submerged in the fluid chamber, such that all operations of the crusher-grinding apparatus are effected within a fluid environment such that produced exhaust gases are trapped.

7. 6. The method of claim 5, wherein the gas outlet mechanism is designed to pass the produced exhaust gas through a scrubber, followed by a compressor and a cooler, such that the gas is compressed and cooled and stored in a container.

8. The method of claim 5 , wherein the temperature of the fluid in the fluid chamber is maintained below the boiling point of the battery's electrolyte solution through active cooling.

9. 6. The method of claim 5, wherein the stirred tank is maintained at a weakly acidic condition by introducing additional fluid into the fluid environment, and once the process is completed, the fluid used in the process is treated to extract dissolved materials, and when the purity of the size components of the materials is not as pure as a pre-set specification, the materials are subjected to thermal shock in hot and cold water and reprocessed in the stirred tank.

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