Systems and methods for the separation of materials from shredded lithium-ion batteries

Abstract

Various embodiments of the present invention provide systems and methods for the separation of materials from shredded lithium-ion batteries. Embodiments also provide an integration mechanism for separating metals, polymers, and black mass from shredded lithium-ion batteries. The present invention provides a system for the classification and separation of shredded materials from lithium-ion batteries through agitation and density separation processes. The system is designed to perform three tasks in a sequential manner. First, the layers of the battery are opened, i.e., the layers of different materials are separated. Second, the polymers and black mass are separated from the layers. Third, the foils of the battery are separated into low / high density materials, suspensions, based on the brittleness of the materials. The present invention provides a system for the optimized separation and sorting of multiple materials from shredded lithium-ion batteries.

Description

Technical Field

[0001] Cross - reference to related applications

[0001] The embodiments of this specification claim the priority of Indian Provisional Patent Application No. 202211023412, filed on April 20, 2022, with the title "SYSTEM AND METHOD FOR SEGREGATION OF MATERIALS FROM SHREDDED LITHIUM - ION BATTERIES", the content of which is hereby incorporated by reference in its entirety.

[0002]

[0002] The present invention generally relates to lithium - ion batteries. More particularly, the present invention relates to systems and methods for the segregation of materials from shredded lithium - ion batteries.

Background Art

[0003]

[0003] The shredding of used lithium - ion batteries is a process that requires special conditions for the safe disposal of the shredded batteries due to the risk of explosion, fire, and other hazards during the shredding process. This process involves the segregation of a plurality of different materials obtained from the shredded lithium - ion batteries.

[0004]

[0004] Current methods for the segregation of materials from shredded lithium - ion batteries are not implemented in most high - temperature metallurgical processes. In wet - refining - based processes, currently, a complex set of processes using some stages of grinding and density separation are used for the segregation of materials. Typically, hammer mills and grinders are used to open the layers, and several classification stages are carried out for the segregation of materials. However, the final products of these processes still contain secondary contamination of multiple materials with respect to each other, so the proper segregation of the extracted materials is not achieved in the wet - smelting process.

[0005] Therefore, an integrated mechanism is needed to separate metals, polymers, and black mass from crushed lithium-ion batteries. Also needed is a system for the classification and separation of crushed materials from lithium-ion batteries through agitation and density separation processes.

[0006]

[0006] The above-mentioned disadvantages, drawbacks, and problems are addressed herein, which will be understood by reading and considering the following detailed description.

Summary of the Invention

Problems to be Solved by the Invention

[0007]

[0007] The main object of the present invention is to provide a system and method for separating materials from crushed lithium-ion batteries.

[0008]

[0008] Another object of the present invention is to provide an integrated mechanism for separating metals, polymers, and black mass by using properties such as high / low density, suspensions, or brittleness from crushed lithium-ion batteries.

[0009]

[0009] Still another object of the present invention is to provide a system for the classification and separation of crushed materials from lithium-ion batteries through agitation and density separation processes.

[0010]

[0010] Yet another object of the present invention is to provide a system for the optimized separation and sorting of multiple materials from crushed lithium-ion batteries.

[0011]

[0011] These and other objects and advantages of the present invention will become readily apparent from the following detailed description in conjunction with the accompanying drawings.

Means for Solving the Problems

[0012]

[0012] Various embodiments of the present invention provide a system and method for the separation of materials from shredded lithium-ion batteries. Embodiments also provide an integration mechanism for separating metals, polymers, and black mass from shredded lithium-ion batteries.

[0013]

[0013] According to one embodiment of the present invention, a system for the separation of materials from shredded lithium-ion batteries is provided. The system includes a large tank for the agitation process, which is mounted to a material inlet mechanism and a material outlet mechanism. The large tank is supported by a frame. The system is designed to perform three tasks in a sequential manner. First, it opens the layers of the battery, i.e., separates the layers of different materials. Second, it separates the polymers and black mass from the layers. Third, it separates the battery foils into low / high density materials and brittle / ductile materials by their sizes. The tank is made of a frame and a skin, with multiple layers. The skin and the inner layer of the tank are made of materials that are not affected by the materials from the shredded battery, such as fluoropolymers, fluroelastomers, and any alloy of nickel, or materials coated with one or more of these materials.

[0014]

[0014] According to one embodiment of the present invention, the shredded lithium-ion battery is introduced into the system through a material inlet mechanism, and then the agitation mechanism is activated. The agitation blade is coupled to a shaft, which is coupled to the rest of the mechanism using a reverse screw, making the shaft easily replaceable. This assembly is supported by a cover using a shaft housing and is mounted to a motor using a belt and pulley system. The entire system is supported by a main frame so that any torque and vibration are not transmitted to the tank and the corresponding tank skin. The cover with the blade and the rotation mechanism includes various ports for sensors and accessories required for monitoring and process control, together with visual slits, a material inlet, and a water inlet spray. The material is then agitated several times at a predetermined time, with various solid / liquid ratios and shaft speeds, and using different shaft blades.

[0015]

[0015] According to one embodiment of the present invention, the material outlet mechanism comprises a sieve provided at the bottom of the tank and a sealed door having a cover. The sieve size is from 250 microns to 5 mm, and the suspension is removed using the sieve. The sieve selection subsequently controls the particle size in the suspension and the black mass. After sieving, water is poured back using an inlet spray, thereby removing the black mass by flushing the precipitated black mass from the low-density material and the high-density material. When a preset level of the black mass of the material is removed and the water becomes clear, the low-density material floats above the water level and it is flowed using an overflow. Then, the sieve door is opened to remove the high-density material.

[0016]

[0016] According to yet another embodiment, the inner skin of the multi-layer tank is perforated and the sieve is replaced with a pump device mounted on the outer layer of the tank device. The agitated material is constantly pumped out of the tank and sent for further processing. Materials having a larger diameter remain in the tank on the perforated layer of the tank and are removed in batches, and the processing parameters and the pumping speed are controlled for the removal of a plurality of materials at different stages.

[0017]

[0017] These and other aspects of the embodiments herein will be better recognized and understood when considered in conjunction with the following description and the accompanying drawings. However, it should be understood that the following description, while showing preferred embodiments and numerous specific details thereof, is provided 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]

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

Brief Description of the Drawings

[0019]

Fig. 1a

Fig. 1b

Fig. 2a

[0020] FIG. 21 is a cross-sectional view of an exemplary implementation of a system for separating materials from a crushed lithium-ion battery according to one embodiment of the present invention.

Fig. 2b

[0020]

[0021] Certain features of the present invention are shown in some drawings but not in others. This is done for simplicity only, as each feature may be combined with any or all of the other features in accordance with the present invention.

[0021]

[0022] 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 that may be practiced. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the embodiments. Accordingly, the following detailed description is not to be taken in a limiting sense.

[0022]

[0023] Various embodiments of the present invention provide systems and methods for separating materials from a crushed lithium-ion battery. Embodiments also provide an integration mechanism for separating metals, polymers, and black mass from a crushed lithium-ion battery.

[0023]

[0024] According to one embodiment of the present invention, a system for the separation of materials from a crushed lithium-ion battery is provided. The system comprises a material inlet mechanism, a stirring device, a support frame, a material separation module, and a material outlet mechanism. The material inlet mechanism is designed to enable a crushed lithium-ion battery to be supplied to the system for separation. The stirring device further comprises a tank structure, a motor, a pulley-belt structure, a stirrer frame, a stirring blade, a shaft, a shaft support unit, a water inlet and a spraying unit, a gas inlet port, a viewing port, and a tank lid. The support frame is designed to support the stirring device. The material separation module is a sieve or a pumping device. The material outlet mechanism is designed to remove the separated material from the system for further processing.

[0024]

[0025] According to one embodiment of the present invention, the tank structure within the stirring device comprises a plurality of layers of tubes and an outer skin layer. The plurality of layers and the outer skin are made of a material that is chemically inert with respect to the components of the chemicals from the crushed battery. The plurality of layers of the tank structure consists of a plurality of materials including stainless steel, polypropylene, fluoropolymer, Fluro elastomer, and some alloy of nickel. The innermost layer is a solid layer contained on the wall of the tank structure, and the intermediate layer between the outer cover layer and the innermost layer comprises a perforated sheet.

[0025]

[0026] According to one embodiment of the present invention, the stirring device is designed to stir the material multiple times at a preset time, different solid-to-liquid ratios, the RPM of the shaft, and with a plurality of shaft configurations. The stirring blade is mechanically coupled to the shaft, and the shaft is further connected to the rest of the system by a reverse thread, thereby making it replaceable. The shaft and the stirring blade assembly are supported by a cover using a shaft housing and are mounted on a motor using a pulley-belt configuration. The entire system is supported by a main frame so that any torque and vibration are not transmitted to the tank and the corresponding skin. The cover with the blade and the rotating mechanism includes a visual slit, a material inlet, and a water inlet and a spray unit together with a plurality of ports for sensors and accessories required for monitoring and process control.

[0026]

[0027] According to one embodiment of the present invention, the material separation module is designed to separate a plurality of materials formed as a result of the stirring of the crushed lithium-ion battery. The plurality of materials includes a plurality of polymers, metal foils, and black masses. The plurality of polymers is obtained in the form of a suspension.

[0027]

[0028] According to one embodiment of the present invention, the material separation module comprises at least one of a sieve or a pumping device. The sieve is provided at the bottom of the tank structure and further includes a sealed door and a cover. The sieve selection control is provided to configure the size of the particles to be separated by sieving in the suspension and the black mass. The water inlet and the spray unit are designed to spray water in the suspension and the black mass to wash the material. The sealed door is designed to open for removing the high-density material that settles at the bottom. The low-density material floating on top of the sprayed water is removed by overflow. According to one embodiment, the sieve is replaced with a pumping device mounted on the outer layer of the tank device, and the agitation material is constantly pumped out of the tank and sent for further processing. The material having a large diameter remains in the tank on the perforated layer of the tank and is removed in batches. The processing parameters and the pumping speed are controlled for removing a plurality of materials at different stages.

[0028]

[0029] According to one embodiment of the present invention, a method for separating materials from a crushed lithium-ion battery is provided. The method includes operating a material inlet mechanism to introduce the crushed lithium-ion battery into an agitation device, separating a plurality of layers and materials in the crushed lithium-ion battery by mechanical agitation in a tank structure within the agitation device, feeding the agitated material mixture to a material separation module for density separation of a plurality of polymers, foils, and black masses obtained after agitation, wherein the material mixture is decomposed based on their ductility ratio, and separately removing the separated materials through a material outlet mechanism for further processing.

[0029]

[0030] According to one embodiment of the present invention, a system for the separation of materials from a crushed lithium ion battery is provided. The system comprises a large tank for the agitation process, which is mounted to a material inlet mechanism and a material outlet mechanism. The large tank is supported by a frame. The system is designed to perform three tasks in a sequential manner. First, the layers of the battery are opened, i.e., the layers of different materials are separated. Second, the polymer and the black mass are separated from the layers. Third, the foils of the battery are separated by the low / high density, suspension, or brittleness of the materials. The tank is made of a frame, for example, a steel pipe having several skin layers, and the skin and the inner layer of the tank are made of a material that is not affected by the materials from the crushed battery, such as a material coated with a fluoropolymer, a fluro elastomer, and some alloy of nickel, or one or more of these materials.

[0030]

[0031] According to one embodiment of the present invention, the crushed lithium ion battery is introduced into the system through a material inlet mechanism, and then the agitation mechanism is activated. The agitation blade is mated with a shaft, and the shaft is mated with the rest of the mechanism using a reverse screw, which allows the shaft to be easily changed. This assembly is supported by a cover using a shaft housing and is mounted to a motor using a belt and pulley system. The entire system is supported by a main frame so that any torque and vibration are not transmitted to the tank and the corresponding skin. The cover with the blade and the rotation mechanism includes various ports for sensors and accessories required for monitoring and process control, together with a visual slit, a material inlet, and a water inlet spray. The material is then agitated several times at a predetermined time, with various solid / liquid ratios and shaft speeds, and using different shaft blades.

[0031]

[0032] According to one embodiment of the present invention, the material outlet mechanism comprises a sieve provided at the bottom of the tank and a sealed door having a cover. The sieve size is from 250 microns to 5 mm, and the suspension is removed using the sieve. The sieve selection subsequently controls the particle size in the suspension and the black mass. After sieving, water is poured back using the inlet spray, thereby removing the black mass by flushing the precipitated black mass from the low-density and high-density materials. When a preset level of the black mass of the material is removed and the water becomes clear, the low-density material floats above the water level and it is flowed using the overflow. Then, the sieve door is opened to remove the high-density material.

[0032]

[0033] According to yet another embodiment, the inner skin of the multi-layer tank is perforated and the sieve is replaced with a pump device mounted on the outer layer of the tank device. The agitated material is constantly pumped out of the tank and sent for further processing. The material having a larger diameter remains in the tank on the perforated layer of the tank and is removed in batches, and the processing parameters and the pumping speed are controlled for the removal of a plurality of materials at different stages.

[0033]

[0034] Figures 1a and 1b respectively illustrate a cross-sectional view and an isometric view of a system for the separation of materials from a crushed lithium-ion battery. The system comprises a blade 101, a sieve 102, a lower cap 103, a shaft 104, a shaft support unit 105, a water inlet 106, a spray unit 107, a tank skin 108, a tank frame 109, an outer frame 110, a motor 111, a pulley and belt unit 112, a water inlet port 113, a material inlet port 114, a viewing port 115, an optical particle separation port 116, and a tank lid 117.

[0034]

[0035] Figures 2a and 2b illustrate a cross-sectional view and an isometric view, respectively, of an exemplary implementation of a system for the separation of materials from a crushed lithium-ion battery. This implementation includes a blade 201, a perforated tank 202, a tank lid 203, a shaft 204, a housing 205, a water inlet port 206, an outer tank 207, an inner tank 208, an agitator frame 209, a motor 210, a pulley and belt unit 211, a gas inlet port 212, and a material outlet port 213.

[0035]

[0036] The embodiments of this specification are described using various specific embodiments, but it is clear that those skilled in the art can practice the embodiments of this specification with modifications.

[0036] Advantages of the Invention

[0037] Various embodiments of the present invention provide a system and method for the separation of materials from a crushed lithium-ion battery. The embodiments also provide an integration mechanism for separating metals, polymers, and black mass from a crushed lithium-ion battery. The present invention provides a system for the classification and separation of crushed materials from a lithium-ion battery through an agitation and density separation process. The present invention provides a system for the optimized separation and sorting of multiple materials from a crushed lithium-ion battery. The present invention reduces any complexity found in conventional processes for material separation and reduces the resource requirements used for the system to function properly.

[0037]

[0038] The foregoing description of the specific embodiments has so fully revealed the general nature of the embodiments herein that they can readily be modified and / or adapted for various applications such as specific embodiments without departing from the higher concept, by applying current knowledge. Accordingly, such adaptations and modifications are intended to be comprehended 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 and not of limitation. Accordingly, the embodiments herein have been described with reference to the preferred embodiments, and one of ordinary skill in the art will recognize that the embodiments herein may be practiced with modifications. However, all such modifications are to be regarded as within the scope of the claims.

Claims

1. A system for the separation of materials from a crushed lithium-ion battery, a material inlet mechanism designed to enable the crushed lithium-ion battery to be supplied to the system for separation, a stirring device further comprising a tank structure, a motor, a pulley-belt structure, a stirrer frame, stirrer blades, a shaft, a shaft support unit, a water inlet and spraying unit, a gas inlet port, a viewing port, and a tank lid, a support frame designed to support the stirring device, a material separation module which is a sieve or a pumping device, a material outlet mechanism designed to remove the separated material from the system for further processing, A system comprising.

2. The tank structure within the stirring device comprises a plurality of layers of tubes and an outer skin layer, and the plurality of layers and the outer skin are made of materials that are chemically inert to the components of the chemicals from the crushed battery. The plurality of layers of the tank structure consist of a plurality of materials including stainless steel, polypropylene, fluoropolymer, fluoroelastomer, and any alloy of nickel. The innermost layer is a solid layer contained on the wall of the tank structure, and the intermediate layer between the outer cover layer and the innermost layer comprises a perforated sheet. The system according to claim 1.

3. The stirring device is designed to stir the material multiple times at a preset time, different solid-to-liquid ratios, RPM of the shaft, and in a plurality of shaft configurations. The stirrer blades are mechanically coupled to the shaft, and the shaft is further connected to the rest of the system by a reverse thread so that the fabricated product is replaceable. The shaft and stirrer blade assembly is supported by the cover using a shaft housing and attached to the motor using a pulley-belt structure. The entire system is supported by a main frame so that no torque and vibration are transmitted to the tank and the corresponding skin. The cover with the blade and rotation mechanism comprises a visual slit, a material inlet, and a water inlet and spraying unit together with a plurality of ports for sensors and accessories required for monitoring and process control. The system according to claim 1.

4. The material separation module is designed to separate a plurality of materials formed as a result of the agitation of the crushed lithium-ion battery, the plurality of materials including a plurality of polymers, metal foils, and black mass, the plurality of polymers being obtained in the form of a suspension, the system according to claim 1.

5. The material separation module comprises at least one of a sieve or a pumping device, the sieve being provided at the bottom of the tank structure, the sieve further including a sealed door and a cover, the sieve selection control being provided to configure the size of the particles to be separated by sieving in the suspension and the black mass, the water inlet and the spraying unit being designed to spray water in the suspension and the black mass to wash the materials, the sealed door being designed to open for removal of the high-density materials settling at the bottom, the low-density materials floating above the sprayed water being removed by overflow, and according to one embodiment, the sieve is replaced by a pumping device mounted on the outer layer of the tank device, the agitated material being constantly pumped out of the tank and sent for further processing, the materials having a large diameter remaining in the tank on the perforated layer of the tank and being removed in batches, the processing parameters and the pumping speed being controlled for removal of the plurality of materials at different stages, the system according to claim 1.

6. A method for separation of materials from a crushed lithium-ion battery, comprising: Actuating a material inlet mechanism to introduce the crushed lithium-ion battery into an agitation device; Separating a plurality of layers and materials in the crushed lithium-ion battery by mechanical agitation in a tank structure within the agitation device; Feeding the agitated material mixture to a material separation module for density separation of a plurality of polymers, foils, and black mass obtained after agitation, the material mixture being decomposed based on their ductility ratio; Separately removing the separated materials through a material outlet mechanism for further processing; A method comprising the above steps.

7. The tank structure within the agitation device comprises a plurality of layers of tubes and an outer skin layer, and the plurality of layers and the outer skin are made of materials that are chemically inert to the components of the chemicals from the crushed battery. The plurality of layers of the tank structure are composed of a plurality of materials including stainless steel, polypropylene, fluoropolymers, fluoroelastomers, and some alloy of nickel. The innermost layer is a solid layer contained on the wall of the tank structure, and the intermediate layer between the outer cover layer and the innermost layer comprises a perforated sheet. The method according to claim 6.

8. The agitation device is designed to agitate the material a plurality of times at a preset time, different solid-to-liquid ratios, RPM of the shaft, and in a plurality of shaft configurations. The agitation blade is mechanically coupled to the shaft, and the shaft is further connected to the rest of the system by a reverse screw so that the fabricated product is replaceable. The shaft and agitation blade assembly is supported by the cover using a shaft housing and mounted to the motor using a pulley-belt configuration. The entire system is supported by the main frame so that no torque and vibration are transmitted to the tank and the corresponding skin. The cover with the blade and rotation mechanism comprises a visual slit, a material inlet, a water inlet, and a spray unit, together with a plurality of ports for sensors and accessories required for monitoring and process control. The method according to claim 6.

9. The material separation module is designed to separate a plurality of materials formed as a result of the agitation of the crushed lithium-ion battery. The plurality of materials include a plurality of polymers, metal foils, and black mass, and the plurality of polymers are obtained in the form of a suspension. The method according to claim 6.

10. The material separation module includes at least one of a sieve or a pump device. The sieve is provided at the bottom of the tank structure, and the sieve further includes a sealed door and a cover. The sieve selection control is provided to configure the size of the particles to be separated by sieving in the suspension and the black mass. The water inlet and the spray unit are designed to spray water in the suspension and the black mass to wash the material. The sealed door is designed to open for removing the high-density material that settles at the bottom. The low-density material floating on top of the sprayed water is removed by overflow. According to one embodiment, the sieve is replaced with a pump device mounted on the outer layer of the tank device. The stirring material is constantly pumped out of the tank and sent for further processing. The material having a large diameter remains in the tank on the perforated layer of the tank and is removed in batches. The processing parameters and the pumping speed are controlled for removing a plurality of materials at different stages. The method according to claim 6.

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