System and method for battery recycling

Abstract

Method for battery recycling using laser materials processing technology. Waste battery material is provided in an enclosure. A laser recycling apparatus is used to recycle the waste battery material—that is, to heat (roast or smelt) at least a portion of the waste battery material to a predetermined temperature for a predetermined time. Metallic product(s) resulting from reduction during the recycling are then removed from the waste battery material. The enclosure may comprise a chamber or container, or may comprise a cover that extends from the laser recycling apparatus to enclosure a volume adjacent the waste battery material. The enclosure comprises at least one outlet that is proximate a filter, and a vapour product of the recycling is captured by the filter. Solid deposits collect on the filter during the recycling step(s) can be recovered once the recycling is complete. In some embodiments, the recycling steps are repeated.

Description

SYSTEM AND METHOD FOR BATTERY RECYCLINGTECHNICAL FIELD

[0001] The present invention relates to battery recycling. More specifically, the present invention relates to recovery of metals and compounds from waste battery material.BACKGROUND

[0002] The widespread use of electronic devices in recent decades, as well as surging growth and interest in renewable and / or sustainable energy sources, has led to an immense demand for batteries throughout many industries. In particular, lithium- ion batteries (LIBs) are widely used in electric vehicles (EVs), electronics and electronic devices, and renewable grids. Typical LIBs can provide several years of service. After those several years, however, the typical LIB is generally unusable due to performance degradation. It is projected that ~1 million tons of used LIBs (which contain hazardous materials) will be extracted from the market by 2025. Of course, such spent LIBs are not environmentally friendly and cannot simply be added to landfills. Additionally, such spent batteries (i.e., waste battery materials) contain various valuable metals and other valuable elements and compounds. Thus, battery recycling allows for the recovery of such elements (allowing for their reuse in new batteries or for producing other metallic alloys), and reduces reliance on virgin resources.

[0003] In principle, hydrometallurgical and pyrometallurgical processes can be used to recycle spent LIBs. Hydrometallurgical methods, however, have the drawbacks of relatively long leaching time and low leaching efficiency, due to the high valence state of the active cathode material and the strong binding force of the organic binders required. Moreover, the vast consumption of concentrated acid and reductants needed in hydrometallurgical processes, and the multiple processing steps required, generate significant effluent, which can exacerbatesecondary pollution from the discharge of acidic wastewater and gas during the leaching processes. Lithium is also dispersed during these separation and refining stages, leading to low lithium recovery rates.

[0004] Compared to hydrometallurgical processes, pyrometallurgical processes have several advantages, such as high productivity, process simplicity, and scalability. However, conventional pyrometallurgical methods for recycling spent batteries have been criticized for their high energy consumption, for the long treatment times required in high-temperature furnaces, and for significant amounts of lithium that are lost in slag.

[0005] Accordingly, there is a need for a more efficient, economical, energy-saving, and environmentally friendly pyrometallurgical process for recycling spent LIBs to recover metals without the drawbacks of conventional methods.SUMMARY

[0006] This document discloses a method for battery recycling using laser materials processing technology (hereinafter referred as laser recycling). Waste battery material is provided in an enclosure adjacent a laser recycling apparatus (i.e., a laser optics head). The laser recycling apparatus is used to roast and smelt the waste battery material — that is, to heat at least a portion of the waste battery material to a predetermined temperature for a predetermined amount of time. Reduction product(s) resulting from the laser recycling (i.e., from roasting in the solid-state at a temperature below the melting point and smelting in the liquid state above the melting point), are then removed from the waste battery material. In some embodiments, the laser recycling is repeated until a predetermined condition is satisfied. The enclosure comprises at least one outlet that is proximate a filter or a particle collector, and a vapour product of the laser recycling passes through the filter or the particle collector. Small particles within the vapour product (such as, for example, particles / molecules of Li2COs) are captured by the filter or by the particle collector as the vapour product passes therethrough. Such particles thereby form deposits that collect on the filter or arecollected by the particle collector during the laser recycling step(s). These deposits can be recovered once the recycling is complete.

[0007] In a first aspect, this document discloses a method for battery recycling, the method comprising:(a) providing waste battery material in an enclosure, said enclosure being provided adjacent a laser recycling apparatus and said enclosure comprising: a laser-transparent layer between said laser recycling apparatus and said waste battery material; and at least one wall connected to said laser-transparent layer;(b) laser recycling said waste battery material using said laser recycling apparatus to thereby produce a reduction product, wherein a vapour product of said laser recycling is captured by a device proximate to said enclosure such that deposits from said vapour product are collected by said device;(c) removing said reduction product from unreduced waste battery material remaining in the enclosure; and(d) recovering said deposits from said device.

[0008] This document also discloses a method wherein said vapour product is a lithium- containing vapour and said deposits comprise lithium-containing compounds.

[0009] This document also discloses a method wherein said waste battery material comprises lithium-ion battery waste.

[0010] This document also discloses a method wherein said reduction product is a metal.

[0011] This document also discloses a method wherein said reduction product is a metallic alloy.

[0012] This document also discloses a method further comprising repeating steps (b)-(c) until a predetermined condition is satisfied.

[0013] This document also discloses a method wherein said predetermined condition is at least one of: a predetermined amount of said unreduced waste battery material remains in said enclosure; a predetermined amount of said reduction product has been removed from said enclosure; a predetermined time for said laser recycling has elapsed; and a predetermined amount of said deposits have been collected by said device.

[0014] This document also discloses a method wherein said enclosure is an enclosed chamber comprising at least one outlet, said at least one outlet being in proximity to said device.

[0015] This document also discloses a method wherein said chamber further comprises a vacuum pump configured to move gases that are within the chamber towards the outlet.

[0016] This document also discloses a method wherein said chamber further comprises at least one inlet on a side of said chamber.

[0017] This document also discloses a method wherein said at least one inlet comprises two inlet nozzles, one of said inlet nozzles injecting a shielding gas into said chamber, said shielding gas flowing adjacent said waste battery material, and another of said inlet nozzles injecting a carrier gas into said chamber, said carrier gas flowing above said shielding gas.

[0018] This document also discloses a method wherein said at least one wall comprises a cover disposed around at least a portion of said waste battery material, said cover attached to said laser recycling apparatus and said cover extending from said laser recycling apparatus to enclose a volume above said at least a portion of said waste battery material.

[0019] This document also discloses a method wherein said waste battery material comprises black mass.

[0020] This document also discloses a method wherein said waste battery material comprises a carbonaceous material.

[0021] This document also discloses a method wherein a reductant for said laser recycling comprises one of: a carbonaceous material, silicon, and aluminum.

[0022] This document also discloses a method wherein said reductant comprises graphite.

[0023] This document also discloses a method wherein said laser recycling apparatus is mobile.

[0024] This document also discloses a method wherein said laser recycling apparatus produces a beam that is perpendicular to said waste battery material in said enclosure.

[0025] This document also discloses a method wherein said laser recycling apparatus produces a beam that is non-perpendicular to said waste battery material in said enclosure.

[0026] This document also discloses a method wherein said waste battery material is provided within a crucible within said enclosure.

[0027] This document also discloses a method further comprising a step of automatically adjusting a power flow to said laser recycling apparatus during step (b) to thereby maintain a temperature of said waste battery material within said enclosure.

[0028] In another aspect, this document discloses a system for battery recycling, the system comprising: a recycling platform for holding waste battery material; a laser recycling apparatus disposed adjacent said recycling platform; and an enclosure, said enclosure comprising: a wall extending from said laser recycling apparatus towards said recycling platform; and a laser-transparent layer connected to said wall, said enclosure thereby enclosing a volume between said recycling platform and said laser-transparent layer.

[0029] This document also discloses a system further comprising a device disposed in proximity to said enclosure, wherein said device is for capturing particles in vapour products of a recycling process, said vapour products being produced within said volume.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present invention will now be described by reference to the following figures, in which identical reference numerals refer to identical elements and in which:Figure 1A is a diagram of an enclosure for implementing an embodiment of the invention;Figure IB is a diagram of an enclosure for implementing another embodiment of the invention;Figure 2 is a diagram of an enclosure for implementing another embodiment of the invention;Figure 3 is an illustration of reduced waste battery material in a powder bed, according to embodiments of the invention;Figure 4 is a diagram of an enclosure for implementing another embodiment of the invention;Figure 5A-5C are diagrams of different enclosures for implementing differing embodiments of the invention;Figures 6A to 6C are photographs showing results of exemplary tests of embodiments of the invention;Figure 7A is a photograph showing results of another exemplary test of an embodiment of the invention;Figure 7B is an energy dispersive spectroscopy spectrum showing elemental results of the test of Figure 7A;Figure 8A is a photograph showing results of another exemplary test of an embodiment of the invention;Figure 8B is an energy dispersive spectroscopy spectrum showing elemental results of the test of Figure 8A;Figures 9A to 9G are photographs of experimental setup and results of other exemplary tests according to embodiments of the invention;Figures 10A and 10B are photographs showing results of exemplary tests of embodiments of the invention;Figure 11A is a flowchart detailing a method according to an aspect of the invention; andFigure 11B is a flowchart detailing a method according to another embodiment of the invention.DETAILED DESCRIPTION

[0031] Some example embodiments and implementations will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. The examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. For clarity, like reference numerals refer to like elements throughout. Furthermore, as used herein, the term "or" is to be interpreted as a logical operator that results in true whenever one or more of its operands are true. As used herein, operable coupling should be understood to relate to direct or indirect connection that, in either case, enables functional interconnection of components that are operably coupled to each other.

[0032] The present invention provides methods for battery recycling using laser materials processing technology (hereinafter referred as laser recycling). Waste battery material is provided within an enclosure. The enclosure is positioned adjacent a laser recycling apparatus (i.e., laser-beam producing optics and associated apparatus) and comprises a laser-transparent layer between the laser recycling apparatus and the waste battery material (i.e., a protective layer that separates the laser recycling apparatus from spatter, vapours, and other productsof the recycling process). The enclosure further comprises at least one wall that is connected to the laser-transparent layer. In embodiments where the enclosure is a laser recycling chamber, the at least one wall may comprise the walls of the chamber. In some “open-concept” embodiments, discussed more below, the at least one wall of the enclosure may comprise a cover / shield that is disposed around at least a portion of the waste battery material but that is not fixed to the bed / recycling platform supporting the waste battery material. A filter is provided proximate to the enclosure (i.e., within the enclosure or in proximity to an outlet of the enclosure).

[0033] Laser recycling is then performed on the waste battery material within the enclosure, causing a reduction reaction in the waste battery material. For example, such laser recycling may follow the reaction of: 4LiMeC>2 (1 or s) + 2C (s) — > Li2COs (1 or g) + Li2O(l or s) + 4Me (1 or s) + 2CO (g) + CO2 (g) (where “Me” means metal, and can be Co, Ni, Mn, and Fe, or a combination thereof; “1” means liquid phase, “s” means solid phase, and “g” means gas phase. Still another example for lithium iron phosphate battery, such laser recycling may follow the reaction of : 4LiFePO4 (1) + 6C(s) + 302(g) — > 2Li2CO3(l or g) + 4FePO4 (1 or s). As should be clear, ‘1 or s’ means either liquid or solid phase would be acceptable, depending on the local temperature and materials melting point.). For clarity, laser recycling involves using a laser beam to heat at least a portion of the waste battery material to a certain high temperature for a certain period of time. During laser recycling, a temperature gradient exists in the heated region. The laser recycling facilitates concurrent smelting and solid-state roasting reduction. Laser recycling involves laser smelting reduction in the region where the temperature is higher than the melting point of materials. Laser recycling also involves solid-state roasting reduction in the region adjacent to the liquid region where the temperature is below the melting point of materials. In contrast to conventional pyrometallurgical process using electric arc furnaces, laser beams do not require long heating times to reach and maintain the needed temperatures. The shorter recycling time associated with laser recycling is also attributed to high temperature and strong surface tension driven flow in the molten pool. As such, although laser recycling requires significant energy input, it can achieve desired reduction results in much shorter times than conventional processes,resulting in substantial energy savings overall. For example, the laser recycling time may be between 5 and 100 seconds. Preferably, the laser recycling time may be between 10 to 50 seconds, and even more preferably, the laser recycling time may be between 20 to 40 seconds. This is substantially shorter than the hours or more that may be required in conventional pyrometallurgical recycling process.

[0034] In some implementations, the laser recycling does not reduce all of the provided waste battery material at once or in one pass, but rather results in a reduction product surrounded by remaining unreduced waste battery material. In such implementations, the reduction product can be removed from the remaining unreduced waste battery material, and the laser recycling can be repeated. Before repeating the laser recycling, in some implementations, additional waste battery material may be added to the enclosure. For example, additional waste battery material may be placed in a space left by removing the reduction product from the remaining unreduced waste battery material. In some such implementations, the laser recycling is iteratively repeated in this way until a predetermined condition is satisfied. Once the predetermined condition is satisfied, the laser recycling is halted and any remaining reduction product(s) collected.

[0035] Additionally, a further product of the laser recycling process is a vapour (i.e., a gaseous product). Depending on the implementation and the chemistry of any specific recycling process, the vapour may comprise CO, CO2 and / or O2, as well as other gases. Additionally, the vapour typically comprises small particles / molecules of other compounds. As the vapour passes through the filter, such particles collect on the filter, thereby forming solid deposits on the filter. Again, the composition of the deposits depends on the composition of the waste battery material and on other factors, but the deposits generally comprise a metal or metal-containing compound. In particular, as in the example above, when the waste battery material is spent LIB material, the vapour product is a lithium- containing vapour and the deposits generally comprise lithium-containing compounds, such as (for example) lithium carbonate (Li2CO3). Lithium carbonate is an important industrial chemical. Its main use is as a precursor tocompounds used in lithium-ion batteries. As such, after the laser recycling is complete, the deposits on the filter can be recovered.

[0036] The predetermined condition to be satisfied may be at least one of the following: that a predetermined amount of said unreduced waste battery material remains in said enclosure; that a predetermined amount of said reduction product has been removed from said enclosure; that a predetermined time for said laser smelting has elapsed; and / or that a predetermined amount of said deposits have collected on said filter. Other conditions may also be relevant, depending on the desired implementation.

[0037] Note that, in some implementations, a single pass of the laser beam / a single laser recycling step may be sufficient to satisfy the predetermined condition. For example, only a small amount of waste battery material may be available for recycling. In such cases, iterative repetition of the laser recycling process would not be required, as the predetermined condition would be already satisfied.

[0038] Note, as well, that in some implementations multiple and repeated applications of the laser beam to the waste battery material may be necessary for a proper laser recycling process such that the desired predetermined condition is achieved. For such implementations, the laser beam is applied to the waste battery material multiple times (i.e. in multiple passes of the laser beam across or into the waste battery material) in a manner similar to how a printing head in a 3D printing process is used. After a number of passes, the recycled products (i.e., the reduction products or the alloys or metals produced) are removed from the enclosure. New waste battery material is then introduced into the enclosure and the process begins anew.

[0039] For clarity, the term “waste battery material”, as used herein, denotes any material component of an electrical energy storage device, such as a cell or battery or a derivative thereof, from which it is desired to recycle one or more of the constituent elements for further use. The waste battery material may have been previously used within an electrical energy storage device or electric car, or any other electronic or electric device. The waste material may, in other embodiments, the material generated during the production of battery materials,including (for example) waste intermediate materials or failed batches of battery material. The recovered metal may be used in any application, including, but not limited to, the production of new batteries.

[0040] The cathodes of batteries, including (without limitation) standard lithium-ion batteries, often include mixed metal oxides as active materials that provide lithium intercalation. These mixed metal oxides may include mixed transitionmetal oxides. The waste battery material, in preferred embodiments, comprises at least one transition-metal-containing compound.

[0041] In some embodiments, the transition-metal-containing compound comprises one or more of lithium, nickel, cobalt, and manganese. In addition, the transitionmetal-containing compound, in some embodiments, may also comprise one or more of iron, aluminum, and copper.

[0042] As examples, the transition-metal-containing compound may be a cobalt- containing oxide. For example, the transition metal-containing compound may be a mixed oxide comprising cobalt and lithium (i.e., a lithium cobalt oxide, or “LCO”). The transition-metal-containing compound, in another embodiment, may be a mixed oxide comprising nickel, lithium, and cobalt (i.e., lithium nickel cobalt oxide, or “LNC”). In another example, the transition-metal-containing compound may comprise lithium, nickel, and manganese (i.e., lithium manganese nickel oxide, or “LMN”). As still another example, the transition-metalcontaining compound may comprise lithium, nickel, manganese, and cobalt (i.e., lithium nickel manganese cobalt oxide, or “NMC”, such as NMC111). In another example, the transition-metal-containing compound may comprise lithium and iron (i. e. , lithium iron phosphate, or LFP).

[0043] In some implementations, the waste battery material comprises black mass obtained from the mechanical disassembly of the battery. The mechanical disassembly of the battery may include shredding the battery pack and / or separating one or more components out from the battery pack. Such “black mass” is a material well known to the person skilled in the art. The black mass comprises a mixture of cathode material (i. e. , the transition-metal-containing compound) and anode material (e.g., graphite-based or other carbonaceousmaterial containing or not containing other elements such as silicon, or silicon- based). Such graphite, graphite-based, or other carbonaceous or silicon-based material contained in the black mass may be useful during the reduction process (i.e., during the laser recycling step(s)), by providing a carbonaceous atmosphere for carbothermic reduction or providing a silicothermic reduction.

[0044] In some implementations, the waste battery material only comprises the cathode material (i.e., the transition-metal-containing compound). When the waste battery material comprises only the cathode material, the method comprises an additional step of mixing graphite powder with the waste battery material before reduction recycling. The percentage of graphite added may range from 5% to 35% depending on the implementation. The percentage of graphite may preferably be between 10% and 25%, and more preferably be between 15% and 20%. The graphite may comprise graphite powder and / or graphite fiber, depending on the implementation. The size of graphite powder may be between 1 micron and 300 microns, preferably between 5 microns and 150 microns, and more preferably between 10 microns and 50 microns.

[0045] In other implementations, instead of graphite, silicon powder may be mixed with the waste battery material before reduction. When using silicon powder as a reductant, the silicon percentage and silicon powder size are the same as detailed above for graphite powder. It should be noted that, when using silicon powder as a reductant, most of the lithium in the waste battery material will react with other oxides and form slags comprising lithium silicates.

[0046] In some implementations, further, the reductant comprises aluminum.

[0047] As well, in some implementations, instead of mixing the waste battery material with graphite or other reductant before laser recycling, reductant, such as graphite, may be fed into the laser heated region during laser recycling through a powder feed nozzle.

[0048] Further, in some implementations, the raw materials (i.e., the waste battery material and graphite powder or other reductant, if used) are deposited onto a substrate, such as a graphite plate, by direct energy laser deposition or laser additive manufacturing. During deposition, the oxides may be reduced to metalor metallic alloy in-situ on the surface of the substrate, and the unreduced powder may be reused as raw material for further deposition reduction.

[0049] Figure 1A is a cutaway diagram of an enclosure for implementing an embodiment of the invention. The enclosure comprises walls 1 and a laser- transparent layer 6 at the top of the walls 1. The waste battery material 2 is provided as a powder bed, and at least a portion 3 of the waste battery material 2 is reduced by exposure to the laser beam 7. Note that, in this figure, the laser recycling apparatus producing the laser beam 7 is not depicted. Additionally, as would be understood, it is generally convenient to arrange a laser beamproducing apparatus (i.e., a “laser recycling apparatus”) adjacent an enclosure and arrange the powder bed on the bottom of the enclosure (as, given the nature of the powder bed, different configurations may be difficult to implement). However, the laser beam need not be directly above the enclosure, nor is the laser-transparent layer 6 required to be at the top of the enclosure. In particular, the laser recycling apparatus may be positioned such that the laser beam is perpendicular or non-perpendicular to the waste battery material, as may be suitable for a given implementation. As such, the laser recycling apparatus, wall(s) 1 and laser-transparent layer 6 may be arranged in any configuration suitable for reducing the waste battery material within the enclosure.

[0050] As should be clear, the laser-transparent layer 6 may comprise any material that is suitably transparent to lasers. Such materials may include, without limitation, glass, sapphire, quartz, and / or fused silica.

[0051] The laser recycling apparatus, as would be understood, generally comprises laser optics and a power source for providing laser energy. The laser optics produce the laser beam. In some embodiments, the laser recycling apparatus is a mobile apparatus. For example, in some such embodiments, the laser optics are mounted on a mobile robot that can move with respect to the waste battery material. (As would be understood, the power source and the laser optics may be physically separated from each other, depending on the embodiment.) Such embodiments may be useful in, for example, recycling processes that use a powder bed. In other embodiments, the laser recycling apparatus comprises a stationary apparatus or largely stationary apparatus. This may be a mobile apparatus usedin a stationary manner or may be a non-mobile apparatus. Such embodiments may be useful in, for example, smelting processes that use a crucible, as described further below.

[0052] The waste battery materials powder bed, in some embodiments, is pressed (i.e., compacted) to a predetermined relative density before the recycling step(s) are performed. In some embodiments, the predetermined relative density is from 10% to 80% of theoretical density. Preferably, the predetermined relative density is from 20% to 65%, and even more preferably, the predetermined relative density is from 40% to 60%.

[0053] In some implementations, the enclosure comprises at least one outlet connected to a pipe or vent tube 10 through which vapour / gas products of the laser recycling process, as well as hot air and / or other exhaust, may vent. In the embodiment depicted in Figure 1A, a fdter 11 is positioned in the vent tube 10. Deposits 12 collect on the fdter 11 as the vapour product of the reduction process is captured by the fdter 11, as described above. In some embodiments, a vacuum pump 14 is positioned at an end of the vent tube 10, to enhance the removal of exhaust gas 13 and the movement of the vapour product through the fdter 11.

[0054] Additionally, as shown in Figure 1 A, the chamber may comprise one or more inlets 4, 5 in the at least one wall(s) 1. The one or more inlets shown are in a wall of the chamber opposite the vent tube 10. However, it would be understood by the person skilled in the art that the inlet(s) may be positioned anywhere around the chamber, depending on the desired implementation. Further, the inlets are preferably capable of injecting gas(es) to the chamber, rather than simply being open inlets that could allow the valuable (and potentially harmful) gaseous product(s) of the reaction to escape. That is, in some embodiments, the inlet(s) 4, 5 comprise nozzles that inject gases into the chamber.

[0055] In Figure 1A, the nozzle 4 injects a shielding gas 8 that flows adjacent (i.e., directly above) the waste battery material 2 and the nozzle 5 injects a carrier gas 9 that flows above the shielding gas 8. The carrier gas 9 helps to collect and move the gaseous product of the recycling process towards and through the fdter 11. Although air or CO2 gas may be used as both of, or either of, the shieldinggas 8 and the carrier gas 9, nitrogen is preferably used for both, and argon is even more preferably used.

[0056] As well, in some embodiments, the laser recycling apparatus moves in a direction 19 as shown in Figure 1 A. (The person skilled in the art would understand that the direction 19 may be any suitable direction.) That is, the laser recycling apparatus in such embodiments is a moving apparatus. The speed of a moving laser beam 7 may be calculated as speed = laser beam size / laser materials interaction time. This equation can, of course, be used to determine the appropriate laser materials interaction time for a given laser beam size and speed. For example, a laser beam moving at a speed of 1 mm / s and having a laser beam size of 30 mm may be used. In such a case, the laser materials interaction (recycling) time will be 30 seconds. As described above and as would be understood, in some embodiments, the motion of the laser beam is controlled by the laser recycling apparatus, for example by a mobile robot to which the laser optics are mounted.

[0057] Further, in some embodiments, the enclosure for the waste battery material may move relative to the laser recycling apparatus. For example, if the waste battery material is in a chamber or container on a table / platform, the chamber or container may move relative to the stationary laser recycling apparatus.

[0058] Figure IB, for example, shows an enclosure similar to the enclosure of Figure 1A but using a stationary laser recycling apparatus and stationary laser beam 7. As can be seen, Figure IB depicts less waste battery material 2 to be reduced than Figure 1A. Additionally, that waste battery material 2 to be reduced in Figure IB is provided within a crucible 20 that is provided within the enclosure. The person skilled in the art would recognize when such a crucible 20 would be useful for smelting processes.

[0059] It should be noted that the laser beam 7 may also be, depending on the embodiment, focused or defocused. As well, depending on the embodiment, the laser beam 7 may be any suitable shape (z.e., circular or square). Square laser beams, in some embodiments, have a beam size from 1 mm to 150 mm, preferably from 10 mm to 100 mm, and more preferably from 20 mm to 50 mm.Theoretically, a laser beam 7 may be any size as long as a predetermined power density can be achieved. The predetermined power density, depending on the embodiment, may be from 2W / mm2to 20W / mm2, preferably from 4W / mm2to 10W / mm2, and more preferably from 5W / mm2to 8W / mm2. In some embodiments, the laser beam power (and thus the laser beam power density) are automatically adjusted during laser recycling to maintain the temperature of the recycling region at a desired level. As should be clear, such automatic adjustment would be controlled by software and hardware of the laser recycling apparatus, including of, for example, a pyrometer associated with the laser recycling apparatus, responsive to initial instructions or settings from an operator of the laser recycling apparatus. The maximum temperature of the smelting region, depending on the embodiment, may be from 1450 to 2500 °C, preferably from 1550 to 2000 °C, and more preferably from 1700 to 1900 °C.

[0060] Figure 2 is a cutaway diagram of another container for implementing the method(s) disclosed herein. The enclosure in Figure 2 is similar to the chambers of Figures 1A and IB, but has no inlets / inlet nozzles. That is, the chamber depicted in Figure 2 is a vacuum chamber.

[0061] Figure 3 is a top-down illustration of a powder bed of waste battery material 2 surrounded by an enclosure’s wall(s) 1. The figure depicts a reduction product 3 which is to be removed from the surrounding waste battery material 2. The dotdash line 4 indicates an exemplary region of waste battery material 2 that will be removed along with the reduction product 3 (e.g, because it adheres to the reduction product on removal, etc.).

[0062] The reduction product, in some embodiments, comprises metal balls of a single metal such as cobalt. In other embodiments, and depending on the chemistry of the raw waste battery material, the reduction product comprises metal alloy balls containing several metals such as cobalt, nickel, and manganese. The metal or alloy balls may have diameters between 2 micrometers and several millimeters, depending on the embodiment. The reduction product(s) may be removed from the unreduced raw waste battery material using a magnetic bar to attract the metal / alloy (depending on the embodiment). Once removed, the adjacent wastebattery material 4 may be further separated from the reduction product and returned to the powder bed, which can be recompacted as necessary.

[0063] Figure 4 illustrates an “open-concept” implementation of the laser recycling process, as mentioned above. The waste battery material 2 and reduced portion / reduction product 3 sit in or on a recycling platform (e.g. , a tray, bed, or other platform). The wall 1 in this figure is a cover that extends from the laser recycling apparatus 15 and encloses a volume adjacent the powder bed of waste battery material 2. However, as can be seen, the lower ends of the cover are not fixed to the sides of the tray in which the waste battery material 2 and reduced portion / reduction product 3 sit. In some embodiments, the length of the cover is adjustable to ensure the lower ends are on the surface of the powder bed. Additionally, the cover is preferably cone-shaped, for efficiency, though other shapes are possible.

[0064] As in Figure 4, laser beam 7 heats a portion 3 of the waste battery material 2 through a laser-transparent layer 6. A shielding gas may be introduced into the recycling region (i.e., the volume enclosed by the cover / wall 1) via inlet 16e. The shielding gas and vapour product leave the cover through outlets 16a, 16b, 16c, and 16d. Each of the outlet(s) is preferably in proximity to a filter 11 to collect deposited metal-containing compounds 12. Depending on the configuration and implementation, vent pipes 10 may be extended within close proximity of the cover / wall 1 using a flexible pipe 18. The laser recycling apparatus 15 and laser beam 7, and thus the cover / wall 1, move across the powder bed in a direction 19.

[0065] Figure 5A shows a cutaway view of another open-concept arrangement for laser recycling according to the present methods. As can be seen, the cover / wall 1 is configured to allow for a non-perpendicular laser beam 7 in this embodiment. Of course, many possible shapes may be suitable for the cover / wall 1, depending on the embodiment.

[0066] Referring to Figure 5B, illustrated is another configuration for an arrangement for laser recycling according to the present methods. It can be seen that the configuration in Fig. 5B is very similar to the configuration in Fig. 5A. It can beseen that the configuration in Fig. 5B includes a cover 17 that closes off or encloses the waste battery material 2. As well, the configuration in Fig. 5B includes inlets 16e that feeds shielding gas into the enclosed space 22 above the waste battery material 2. The cover 17 sits atop the top surface of the enclosure walls and closes off the enclosed space 22.

[0067] Referring to Figure 5C, illustrated is a further configuration for an arrangement for laser recycling according to the present methods. As can be seen, the configuration in Fig. 5C is similar to the configuration in Fig. 5B. The only difference is that, while the configuration in both Figs. 5B and 5C use a vacuum 14, the configuration in Fig. 5B uses a filter 11 to collect deposited metalcontaining compounds 12. In the configuration in Fig. 5C, instead of a filter between the vacuum 14 and the inside 22 of the enclosure, a particle collector 20 is provided such that the vacuum 14 is between the particle collector 20 and the inside 22 of the enclosure. This configuration is provided to avoid the deposition of particles (e.g, Li2CO3) on the filter. In the configuration in Fig. 5B, the deposition of particles on the filter blocks the gas flow and this necessitates frequent changing of the filter. However, in the configuration in Fig. 5C, by placing the particle collector 20 after the vacuum 14, one can achieve longer recycling times without needing to change the filter.Examples

[0068] Numerous exemplary tests were performed and will be described below. Nothing in any of the tests described below should be considered to limit the invention herein in any way.Example 1 (Fig 6A)

[0069] A powder mixture was prepared using a rotation powder mixer for 1 hour. The powder mixture comprised 80% weight percent LiCoCh powder (having powder sizes of about 7 to 12 micrometers) and 20% weight percent graphite powder (having powder sizes of about 5 to 20 microns). The mixed powder was then pressed to a pellet with a relative density of 65% with a diameter of 12.5 mm and a height of 15 mm, then placed in a graphite crucible. The graphite crucible was placed in a chamber as in Figure IB. A fiber laser beam with a power of 2010 Wand a beam size of 20 mm in diameter at the focal point was used to heat the mixed powder pellet for 30 seconds under argon as the shielding gas and air as the carrier gas. After laser recycling (exposure), a cobalt metal ball remained in the crucible, as shown in Figure 6A.Example 2 (Fig 6B)

[0070] The steps of Example 1 were followed, except that both the shielding gas and the carrier gas used were air, rather than argon and air respectively. The cobalt metal ball reduction product of this test is shown in Figure 6B.Example 3 (Fig 6C)

[0071] The steps of Example 1 were followed, except that (i) the recycling was carried out with a laser power of 1800 W for 40 seconds; (ii) the carrier gas was argon; and (iii) no shielding gas was used. The cobalt metal ball reduction product of this test is shown in Figure 6C.Example 4 (Figs 7A and 7B)

[0072] LiNio.33Mno.33Coo.33O2 powder with a diameter of 12 microns was mixed with graphite powder with a diameter of 5 to 25 microns. The mixture had a composition of 80% LiNio.33Mno.33Coo.33O2 powder and 20% graphite powder. The mixed powder was pressed to a pellet with a relative density of 70% with a diameter of 12.5 mm and a height of 15 mm, then placed in a graphite crucible. Again, the graphite crucible was placed in a smelting chamber as in Figure IB. A fiber laser beam with a power of 1600 W and a beam size of 20 mm in diameter at the focal point was used to heat and smelt the mixed powder pellet for 40 seconds under argon shielding gas 8 and air carrier gas 9. After smelting, an alloy ball containing cobalt, nickel, and manganese was produced in the crucible, as shown in Figure 7A. Figure 7B shows the energy dispersive spectroscopy spectrum of the various elements in the alloy ball thus produced.Example 5 (Figs 8A and 8B)

[0073] LiCoCh powder with diameters about 7 to 12 micrometers was mixed with silicon powder having diameters about 10 to 40 microns using a rotation powder mixerfor 1 hour. The powder mixture was 80% weight percent LiCoO2 powder and 20% weight percent silicon powder. 3 grams of the mixed powder was pressed by hand into a pellet, then placed in a graphite crucible. The graphite crucible was placed in a smelting chamber as in Figure IB. A laser beam 7 with a power of 4000 W and a beam size of 25 mm by 25 mm square at the focal point was used to heat and smelt the mixed powder pellet for 30 seconds under air shielding gas and air carrier gas. After smelting, a silicon-containing cobalt ball was produced in the crucible, as shown in Figure 8A and the corresponding energy dispersive spectroscopy spectrum in Figure 8B.Example 6 (Figs 9A to 9D)

[0074] A powder mixture was prepared using a rotation powder mixer for 1 hour. The powder mixture had 80% weight percent LiCoCh powder, diameter about 7 to 12 micrometers, and 20% weight percent graphite powder, diameter about 5 to 20 microns. The mixed powder was put into an enclosure to form a powder bed, as shown in Figure 9A. A stationary fiber laser beam with a power of 2010 W and a beam size of 20 mm in diameter at the focal point was used to heat and smelt the powder bed for 30 seconds under argon shielding gas and vacuum. After laser exposure , a cobalt metal piece was produced in the powder bed, as shown in Figure 9B. Figure 9C shows the powder bed after removing the reduced metal piece, and Figure 9D shows the removed metal piece with the adhered powder.Example 7 (Figs 9E to 9G)

[0075] The steps of Example 6 were followed, except that the laser beam moved at a speed of 1 mm / s. The powder bed is shown in Figure 9E. The reduction product formed in the powder bed is shown in Figure 9F. The remaining powder bed after removal of the reduction product is shown in Figure 9G.Example 8 (Figs 10A and 10B)

[0076] LiNio.33Mno.33Coo.33O2 powder with a diameter of 12 micron was mixed with graphite powder with a diameter of 5 to 25 micron. The mixture had a composition of 80% weight percent LiNio.33Mno.33Coo.33O2 and 20% weightpercent graphite. The mixed powder was pressed into a large pellet with a diameter of 38 mm and a height of 28 mm with a relative density of 70%, then in an enclosure as the powder bed 2. A fiber laser beam with a power of 1600 W and a beam size of 20 mm in diameter at the focal point was used to heat and smelt the pellet for 40 seconds under argon shielding gas and nitrogen carrier gas. After smelting, an alloy ball containing cobalt, nickel, and manganese was reduced in the powder bed, as shown in Figure 10A. When the laser beam moved at a speed of 0.5 mm / s, many alloy balls formed in the powder bed, as shown in Figure 10B.Method Flowcharts

[0077] Figure 11A is a flowchart detailing a method according to an aspect of the invention. At step 1100, waste battery material is provided. Laser recycling is performed at step 1110. At step 1120, the reduction product is removed. Deposits are collected from the fdter at step 1130.

[0078] Figure 11B is a flowchart detailing a method according to an embodiment of the invention in which the recycling steps are repeated. Accordingly, most of the steps are similar to the steps depicted in Figure 11 A. Again at step 1100, waste battery material is provided. Laser recycling is performed at step 1110 and the reduction product is removed at step 1120. At decision 1125, if the predetermined condition is not satisfied, steps 1110 and 1120 are repeated. If the predetermined condition is satisfied at decision 1125, no more laser recycling steps are conducted, and the deposits are collected from the filter at step 1130.

[0079] As used herein, the expression “at least one of [x] and [y]” means and should be construed as meaning “[x], [y], or both [x] and [y]” Further, all ranges are inclusive (i.e., the expressions “between [x] and [y]”, “[x] to [y]” and “from [x] to [y]” indicate ranges that include both [x] and [y]). As well, the expression “about [#]” means “[#] plus-or-minus 10% of [#]”.

[0080] It should also be understood that, although features of the invention described above may be described in reference to distinct embodiments, any and all features that can cooperate with each other may do so. That is, the invention encompasses all possible combinations of the features of the invention, including as separatelydescribed above, without limitation. As one specific and non-limiting example, various relative densities of the powder bed are described above with reference to the embodiment shown in Figure 1A. However, powder beds having such relative densities may be used in any other embodiment of the laser recycling apparatus, system, and / or method. Similarly, all other features described above should be understood to apply to any and all embodiments of the invention, as may be suitable or desirable.

[0081] In one embodiment, the methods and system of the invention include a laser recycling chamber. The chamber may be mobile or stationary. A filter proximate to the cover captures vapour product(s) produced during the recycling, such that deposits from said vapour product collect on the filter. The chamber has one or more inlet(s) and / or inlet nozzle(s). The inlet nozzle(s), if used, may introduce one or both of a shielding gas and a carrier gas. The shielding gas may be any of CO2, air, nitrogen, and / or argon. The carrier gas may be any of CO2, air, nitrogen, and / or argon. The material to be recycled in the chamber (i.e., the waste battery material) may be in the form of a pellet or may be arranged in a bed or a crucible. If a bed of material is used, the relative density of the bed may be from 10% to 80%, inclusive; preferably from 20% to 65%, inclusive; and more preferably, from 40% to 60%, inclusive. If a pellet of material is used, the relative density of the bed may be from 10% to 80%, inclusive; preferably from 20% to 65%, inclusive; and more preferably, from 40% to 60%, inclusive. The waste battery material comprises any material component of an electrical energy storage device from which it is desired to recycle one or more constituent elements. The waste battery material may include one or more of: black mass; cathode material (and / or reductant); and transition-metal-containing compound(s). The transition-metal-containing compound(s) may comprise Li, Ni, Co, Mn, Fe, Al, Cu, and / or combinations thereof. The transition-metalcontaining compound(s) may comprise oxides such as, without limitation, lithium cobalt oxide (e.g, LiCoCh), lithium nickel cobalt oxide, and / or lithium nickel manganese cobalt oxide (e.g, LiNixMnyCozO2). If a reductant is used, the reductant may comprise graphite powder, graphite fibre, silicon powder, and / or aluminum. The reductant may comprise between 5% and 35% (inclusive) of the waste battery material by weight; preferably between 10% and 25% (inclusive);and more preferably between 15% and 20% (inclusive). If the reductant is in a powdered form, the powder size may be between 1 micron to 300 microns, inclusive; preferably between 5 microns and 150 microns, inclusive; and more preferably between 10 microns and 50 microns, inclusive. The laser used in this embodiment may be mobile or stationary. The angle of the laser beam with respect to the material to be recycled may be perpendicular or non-perpendicular. The laser beam may be focused or unfocused. The laser beam may be circular or square or any other shapes. The laser beam may be any size sufficient to achieve a predetermined power density. The power density may be between 2W / mm2and 20W / mm2, inclusive; preferably between 4W / mm2and 10W / mm2, inclusive; and more preferably between 5W / mm2and 8W / mm2, inclusive. (Thus, for example, depending on the power of the laser apparatus, if a square laser beam is used, the side lengths of the laser beam square may be between 1 mm and 150 mm, inclusive; preferably from 10 mm to 100 mm, inclusive; and more preferably from 20 mm to 50 mm, inclusive.) The laser recycling time (i.e., interaction time between laser beam and materials) may be between 5 seconds and 100 seconds, inclusive; preferably between 10 to 50 seconds, inclusive; and more preferably between 20 to 40 seconds, inclusive. One or more laser recycling passes may be used during continuous recycling in a powder bed. The maximum temperature of the recycling region may be between 1450°C to 2500°C, inclusive; preferably from 1550 to 2000 °C, inclusive; and more preferably from 1700 to 1900 °C, inclusive. Parameters of the laser may be automatically adjusted during recycling and / or adjusted when recycling is not being performed.

[0082] In one embodiment, the methods and system of the invention include a laser recycling chamber. The chamber may be mobile or stationary. The chamber has no inlets or inlet nozzles (i.e., the chamber is a vacuum chamber). A fdter proximate to the chamber captures vapour product(s) produced during the recycling, such that deposits from said vapour product collect on the fdter. The material to be recycled in the chamber (i.e., the waste battery material) may be in the form of a pellet or may be arranged in a bed or a crucible. If a bed of material is used, the relative density of the bed may be from 10% to 80%, inclusive; preferably from 20% to 65%, inclusive; and more preferably, from 40% to 60%, inclusive. If a pellet of material is used, the relative density of the bed may befrom 10% to 80%, inclusive; preferably from 20% to 65%, inclusive; and more preferably, from 40% to 60%, inclusive. The waste battery material comprises any material component of an electrical energy storage device from which it is desired to recycle one or more constituent elements. The waste battery material may include one or more of: black mass; cathode material (and / or reductant); and transition-metal-containing compound(s). The transition-metal-containing compound(s) may comprise Li, Ni, Co, Mn, Fe, Al, Cu, and / or combinations thereof. The transition-metal-containing compound(s) may comprise oxides such as, without limitation, lithium cobalt oxide (e.g, LiCoCL), lithium nickel cobalt oxide, and / or lithium nickel manganese cobalt oxide (e.g, LiNixMnyCozO2). If a reductant is used, the reductant may comprise graphite powder, graphite fibre, silicon powder, and / or aluminum. The reductant may comprise between 5% and 35% (inclusive) of the waste battery material by weight; preferably between 10% and 25% (inclusive); and more preferably between 15% and 20% (inclusive). If the reductant is in a powdered form, the powder size may be between 1 micron to 300 microns, inclusive; preferably between 5 microns and 150 microns, inclusive; and more preferably between 10 microns and 50 microns, inclusive. The laser used in this embodiment may be mobile or stationary. The angle of the laser beam with respect to the material to be smelted may be perpendicular or non-perpendicular. The laser beam may be focused or unfocused. The laser beam may be circular or square or any other shapes. The laser beam may be any size sufficient to achieve a predetermined power density. The power density may be between 2W / mm2and 20W / mm2, inclusive; preferably between 4W / mm2and lOW / mm2, inclusive; and more preferably between 5W / mm2and 8W / mm2, inclusive. (Thus, for example, depending on the power of the laser apparatus, if a square laser beam is used, the side lengths of the laser beam square may be between 1 mm and 150 mm, inclusive; preferably from 10 mm to 100 mm, inclusive; and more preferably from 20 mm to 50 mm, inclusive.) The laser smelting time may be between 5 seconds and 100 seconds, inclusive; preferably between 10 to 50 seconds, inclusive; and more preferably between 20 to 40 seconds, inclusive. One or more laser smelting passes may be used. The maximum temperature of the smelting region may be between 1450°C to 2500°C, inclusive; preferably from 1550 to 2000 °C, inclusive; and more preferably from1700 to 1900 °C, inclusive. Parameters of the laser may be automatically adjusted during smelting and / or adjusted when smelting is not being performed.

[0083] In one embodiment, the methods and system of the invention include an openconcept embodiment in which a cover extends from a laser recycing apparatus to enclose a volume adjacent at least a portion of the waste battery material to be smelted. A filter proximate to the cover captures vapour product(s) produced during the smelting, such that deposits from said vapour product collect on the filter. The cover may have one or more inlet(s) and / or inlet nozzle(s). The inlet nozzle(s), if used, may introduce one or both of a shielding gas and a carrier gas. The shielding gas may be any of CO2, air, nitrogen, and / or argon. The carrier gas may be any of CO2, air, nitrogen, and / or argon. The material to be smelted (i.e., the waste battery material) may be in the form of a pellet or may be arranged in a bed or a crucible. If a bed of material is used, the relative density of the bed may be from 10% to 80%, inclusive; preferably from 20% to 65%, inclusive; and more preferably, from 40% to 60%, inclusive. If a pellet of material is used, the relative density of the bed may be from 10% to 80%, inclusive; preferably from 20% to 65%, inclusive; and more preferably, from 40% to 60%, inclusive. The waste battery material comprises any material component of an electrical energy storage device from which it is desired to recycle one or more constituent elements. The waste battery material may include one or more of: black mass; cathode material (and / or reductant); and transition-metal-containing compound(s). The transition-metal-containing compound(s) may comprise Li, Ni, Co, Mn, Fe, Al, Cu, and / or combinations thereof. The transition-metalcontaining compound(s) may comprise oxides such as, without limitation, lithium cobalt oxide (e.g, LiCoCh), lithium nickel cobalt oxide, and / or lithium nickel manganese cobalt oxide (e.g, LiNixMnyCozO2). If a reductant is used, the reductant may comprise graphite powder, graphite fibre, silicon powder, and / or aluminum. The reductant may comprise between 5% and 35% (inclusive) of the waste battery material by weight; preferably between 10% and 25% (inclusive); and more preferably between 15% and 20% (inclusive). If the reductant is in a powdered form, the powder size may be between 1 micron to 300 microns, inclusive; preferably between 5 microns and 150 microns, inclusive; and more preferably between 10 microns and 50 microns, inclusive. The laser used in thisembodiment may be mobile or stationary. The angle of the laser beam with respect to the material to be smelted may be perpendicular or non-perpendicular. The laser beam may be focused or unfocused. The laser beam may be circular or square or any other shapes. The laser beam may be any size sufficient to achieve a predetermined power density. The power density may be between 2W / mm2and 20W / mm2, inclusive; preferably between 4W / mm2and 10W / mm2, inclusive; and more preferably between 5W / mm2and 8W / mm2, inclusive. (Thus, for example, depending on the power of the laser apparatus, if a square laser beam is used, the side lengths of the laser beam square may be between 1 mm and 150 mm, inclusive; preferably from 10 mm to 100 mm, inclusive; and more preferably from 20 mm to 50 mm, inclusive.) The laser smelting time may be between 5 seconds and 100 seconds, inclusive; preferably between 10 to 50 seconds, inclusive; and more preferably between 20 to 40 seconds, inclusive. One or more laser smelting passes may be used. The maximum temperature of the smelting region may be between 1450°C to 2500°C, inclusive; preferably from 1550 to 2000 °C, inclusive; and more preferably from 1700 to 1900 °C, inclusive. Parameters of the laser may be automatically adjusted during recycling and / or adjusted when recycling is not being performed.

[0084] In one embodiment, the methods and system of the invention include an embodiment in which a cover extends from a laser recycling apparatus to enclose a volume adjacent at least a portion of the waste battery material to be smelted. A vacuum captures vapour product(s) produced during the smelting and the vacuum sends this vapour product(s) to a particle collector such that deposits from said vapour product are collected by the particle collector. The cover may have one or more inlet(s) and / or inlet nozzle(s). The inlet nozzle(s), if used, may introduce one or both of a shielding gas and a carrier gas. The shielding gas may be any of CO2, air, nitrogen, and / or argon. The carrier gas may be any of CO2, air, nitrogen, and / or argon. The material to be smelted (i.e., the waste battery material) may be in the form of a pellet or may be arranged in a bed or a crucible. If a bed of material is used, the relative density of the bed may be from 10% to 80%, inclusive; preferably from 20% to 65%, inclusive; and more preferably, from 40% to 60%, inclusive. If a pellet of material is used, the relative density of the bed may be from 10% to 80%, inclusive; preferably from 20% to 65%,inclusive; and more preferably, from 40% to 60%, inclusive. The waste batery material comprises any material component of an electrical energy storage device from which it is desired to recycle one or more constituent elements. The waste batery material may include one or more of: black mass; cathode material (and / or reductant); and transition-metal-containing compound(s). The transitionmetal-containing compound(s) may comprise Li, Ni, Co, Mn, Fe, Al, Cu, and / or combinations thereof. The transition-metal-containing compound(s) may comprise oxides such as, without limitation, lithium cobalt oxide (e.g, LiCoCh). lithium nickel cobalt oxide, and / or lithium nickel manganese cobalt oxide (e.g, LiNixMnyCozCL). If a reductant is used, the reductant may comprise graphite powder, graphite fibre, silicon powder, and / or aluminum. The reductant may comprise between 5% and 35% (inclusive) of the waste batery material by weight; preferably between 10% and 25% (inclusive); and more preferably between 15% and 20% (inclusive). If the reductant is in a powdered form, the powder size may be between 1 micron to 300 microns, inclusive; preferably between 5 microns and 150 microns, inclusive; and more preferably between 10 microns and 50 microns, inclusive. The laser used in this embodiment may be mobile or stationary. The angle of the laser beam with respect to the material to be smelted may be perpendicular or non-perpendicular. The laser beam may be focused or unfocused. The laser beam may be circular or square or any other shapes. The laser beam may be any size sufficient to achieve a predetermined power density. The power density may be between 2W / mm2and 20W / mm2, inclusive; preferably between 4W / mm2and 10W / mm2, inclusive; and more preferably between 5W / mm2and 8W / mm2, inclusive. (Thus, for example, depending on the power of the laser apparatus, if a square laser beam is used, the side lengths of the laser beam square may be between 1 mm and 150 mm, inclusive; preferably from 10 mm to 100 mm, inclusive; and more preferably from 20 mm to 50 mm, inclusive.) The laser smelting time may be between 5 seconds and 100 seconds, inclusive; preferably between 10 to 50 seconds, inclusive; and more preferably between 20 to 40 seconds, inclusive. One or more laser smelting passes may be used. The maximum temperature of the smelting region may be between 1450°C to 2500°C, inclusive; preferably from 1550 to 2000 °C, inclusive; and more preferably from 1700 to 1900 °C, inclusive.Parameters of the laser may be automatically adjusted during recycling and / or adjusted when recycling is not being performed.

[0085] Again, any combination of parameters, features, and / or properties disclosed above may be implemented by the person skilled in the art, in any embodiment of the invention.

[0086] A person understanding this invention may now conceive of alternative structures and embodiments or variations of the above all of which are intended to fall within the scope of the invention as defined in the claims that follow.

Claims

We claim:

1. A method for battery recycling, the method comprising:(a) providing waste battery material in an enclosure, said enclosure being provided adjacent a laser recycling apparatus and said enclosure comprising: a laser-transparent layer between said smelting apparatus and said waste battery material; and at least one wall connected to said laser-transparent layer;(b) laser recycling said waste battery material using said laser recycling apparatus to thereby produce a reduction product, wherein a vapour product of said laser recycling is captured by a device proximate to said enclosure such that deposits from said vapour product are collected by said device;(c) removing said reduction product from unreduced waste battery material remaining in the enclosure; and(d) recovering said deposits from said device.

2. The method according to claim 1, wherein said vapour product is a lithium-containing vapour and said deposits comprise lithium-containing compounds.

3. The method according to claim 1, wherein said waste battery material comprises lithium-ion battery waste.

4. The method according to claim 1, wherein said reduction product is a metal.

5. The method according to claim 1, wherein said reduction product is a metallic alloy.

6. The method according to claim 1, further comprising repeating steps (b)-(c) until a predetermined condition is satisfied.

7. The method according to claim 6, wherein said predetermined condition is at least one of: a predetermined amount of said unreduced waste battery material remains in said enclosure; a predetermined amount of said reduction product has been removed from said enclosure; a predetermined time for said laser recycling has elapsed; and a predetermined amount of said deposits have been collected by said device.

8. The method according to claim 1, wherein said enclosure is an enclosed chamber comprising at least one outlet, said at least one outlet being in proximity to said device.

9. The method according to claim 8, wherein said chamber further comprises a vacuum pump configured to move gases that are within the chamber towards the outlet.

10. The method according to claim 8, wherein said chamber further comprises at least one inlet on a side of said chamber.

11. The method according to claim 10, wherein said at least one inlet comprises two inlet nozzles, one of said inlet nozzles injecting a shielding gas into said chamber, said shielding gas flowing adjacent said waste battery material, and another of said inlet nozzles injecting a carrier gas into said chamber, said carrier gas flowing above said shielding gas.

12. The method according to claim 1, wherein said at least one wall comprises a cover disposed around at least a portion of said waste battery material, said cover attached to said laser recycling apparatus and said cover extending from said laser recycling apparatus to enclose a volume adjacent said at least a portion of said waste battery material.

13. The method according to claim 1, wherein said waste battery material comprises black mass.

14. The method according to claim 1, wherein said waste battery material comprises a carbonaceous material.

15. The method according to claim 1, wherein a reductant for said laser recycling comprises one of: a carbonaceous material, silicon, and aluminum.

16. The method according to claim 15, wherein said reductant comprises graphite.

17. The method according to claim 1, wherein said laser recycling apparatus is mobile.

18. The method according to claim 1, further comprising a step of automatically adjusting a power flow to said laser recycling apparatus during step (b) to thereby maintain a temperature within said enclosure.

19. The method according to claim 1 wherein step b) is accomplished by processing said waste battery material, said processing being at least one of roasting reduction and smelting reduction.

20. The method according to claim 1 wherein said device is a fdter.

21. The method according to claim 1 wherein said device is a particle collector.

22. A system for battery recycling, the system comprising: a recycling platform for holding waste battery material; a laser recycling apparatus disposed adjacent said recycling platform; and an enclosure, said enclosure comprising: a wall extending from said laser recycling apparatus towards said recycling platform; anda laser-transparent layer connected to said wall, said enclosure thereby enclosing a volume between said recycling platform and said laser- transparent layer.

23. The system according to claim 19, further comprising a device disposed in proximity to said enclosure, wherein said device is for capturing particles in vapour products of a recycling process, said vapour products being produced within said volume.

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