Plant and method for handling battery material dust

Abstract

The present invention relates to the recycling of used lithium ion batteries and provides a plant for recycling battery materials and a method for handling black mass dusts derived from lithium ion batteries.

Description

[0001] BASF SE B25.179P-EP

[0002] 67056 Ludwigshafen am Rhein 25.09.2025 / lg / jl

[0003] Plant and method for handling battery material dust

[0004] Field of the invention

[0005] The present disclosure relates to a plant for recycling battery materials, and to a method for safe handling battery material dust produced in a recycling process of battery materials.

[0006] Background

[0007] Lithium ion battery materials contain valuable metals such as lithium, aluminum, copper, nickel, cobalt, and / or manganese that can be recovered and recycled to conserve natural resources. Processes for recycling lithium ion battery materials generally comprise mechanical comminution of lithium ion batteries, lithium ion battery waste, lithium ion battery production scrap, lithium ion cell production scrap, or lithium ion cathode active material to obtain black mass, a particulate material comprising the active components of the battery electrodes such as graphite and cathode active material, which may also include impurities from the casing, electrode foils, cables, separator, and electrolyte. The black mass then is further processed to recover the valuable metals, for instance, by hydrometallurgical treatment.

[0008] The black mass may be in powder form, also referred to as black mass dust. Such black mass dusts are toxic (genotoxic) and carcinogenic and the particles are very fine and volatile and, therefore, hazardous to the health of people who are tasked with further processing the black mass. When it comes to unloading, transferring and loading black mass, any dust emissions into the atmosphere must be avoided to protect operators against the risk of contamination. Occupational exposure to black mass dust may occur through inhalation of dust particles and fumes or through skin contact.

[0009] EP 4 144 450 A1 refers to a method for cleaning exhaust air generetad in a processing process in a clean room and a system for carrying out the method. During the cleaning process, exhaust air generated in a clean room / dry room is extracted from a process area and fed to a filter unit. Clean air / dry air is taken from the clean room / dry room and fed to the process area as a volume flow, which captures and carries away emissions occurring in the process area. A further part of the clean air / dry air of the clean room / dry room is used to form at least one cross flow which is directed transversely against the volume flow and shields the process area from the clean room / dry room.

[0010] It is an object of the present disclosure to provide a plant for recycling battery materials and for handling black mass dust produced in a recycling process of battery materials and a method for handling black mass dust produced during a recycling process of battery materials.

[0011] Summary of the invention

[0012] A first aspect of the invention is a plant for recycling battery materials wherein the plant is configured to receive battery material dust, such as black mass dust, produced during a recycling process in a dust handling compartment, treat it in the dust handling compartment and transfer it to a processing compartment for further processing. The plant comprises at least one processing compartment, a dust handling compartment, also referred to as a black area, and at least one material transfer device, wherein the dust handling compartment is a confined space. The dust handling compartment is structurally separated from the at least one processing compartment and may be lockable and / or sealed against the at least one processing compartment, so that no unwanted exchange of substances is possible. The dust handling compartment and the processing compartment are connected and accessible to each other via the at least one material transfer device. The at least one material transfer device is configured to allow controlled pressure transitions from the dust handling compartment to the outside of the dust handling compartment and vice versa, when opening and closing. The plant further comprises at least one control module which is configured to control operating parameters of the dust handling compartment, wherein as such operating parameters at least a pressure, i.e. an air pressure, within the dust handling compartment is to be controlled or is controlled, wherein the pressure is controlled to lie within a range of 15 Pa to 50 Pa below the ambient pressure outside the plant. The plant comprises at least one mixing vessel in the dust handling compartment to treat battery material dust produced during a recycling process by preparing a slurry from the battery material dust and a liquid, and conveyor means, such as a pump system, for transferring the treated battery material dust, i.e. the slurry, via the at least one material transfer device from the dust handling compartment to the processing compartment for further processing.

[0013] In some embodiments, the control module is configured to continuously control the operating parameters of the dust handling compartment. In some embodiments, the control module is configured to control the operating parameters of the dust handling compartment in regular or irregular intervals.

[0014] In some embodiments, the control module is located inside the dust handling compartment. In some embodiments, the control module is located outside the dust handling compartment, e.g. on an outside wall of the dust handling compartment.

[0015] In some embodiments, the plant further comprises at least one personnel sluice. The dust handling compartment and the processing compartment are connected and accessible to each other also via the at least one personnel sluice. In some embodiments, the plant further comprises at least one personnel sluice through which a person can enter and exit the dust handling compartment directly from outside the plant. The at least one personnel sluice is configured to allow controlled pressure transitions from the dust handling compartment to the outside of the dust handling compartment and vice versa when opening and closing. The personnel sluice is further configured to allow people to enter the dust handling compartment from the outside to work in the dust handling compartment and leave the dust handling compartment to go outside again. The personnel sluice may be separate from or structurally combined with the material transfer device. Some activities for treating I handling battery material dusts in the dust handling compartment can also be controlled from outside the dust handling compartment, i.e. no person has to enter the dust handling compartment, but can control devices for treating the battery material dusts in the dust handling compartment by a kind of remote control.

[0016] In the scope of the present disclosure, the terms "powder" and "dust" are used synonymously with each other. In the scope of the present disclosure, the terms "personnel sluice"; "personnel lock" and "personnel air lock" are used synonymously with each other. In the scope of the present disclosure, the terms "pressure" and "air pressure" are used synonymously with each other.

[0017] In some embodiments, with closed material transfer device and, if available, with closed personnel sluice, the dust handling compartment is hermetically sealed against its surroundings. That means that the dust handling compartment is sealed or can be closed in a way that does not allow any air or other substances to leave or enter the dust handling compartment unintentionally. The dust handling compartment is a confined space, particularly a confined space featuring controlled air pressure and, optionally, controlled humidity (air humidity).

[0018] The dust handling compartment is designed to allow the handling of battery materials, especially battery material dusts. Those battery material dusts may originate from the processing of CAM, from the processing of MHP and / or from the hydrometallurgical part of battery recycling, comprising mainly black mass refinement. Handling means treating without allowing harmful dust particles to reach outside the dust handling compartment. That means that no respirable dust particles are set free (i.e. reach outside the dust handling compartment) when battery material dust, e.g. black mass dust is treated in the dust handling compartment.

[0019] In the scope of the present disclosure, the processing compartment of the recycling plant can include any area or all areas of the recycling plant outside the device, particularly outside the dust handling compartment, preferably areas where battery materials are otherwise processed. It is possible that the processing compartment is an essentially dust-free area or at least only powders are processed in the processing compartment whose particle sizes are not potentially dangerous to human health, e.g. powders with particles with an aerodynamic diameter xae> 10 micrometer (>10pm). A definition of aerodynamic diameter according to EN 481 is given as follows: The aerodynamic diameter is the diameter of a sphere whose density is 1 g cm-3and which has the same terminal velocity due to gravitational force in calm air, as the particle, under the prevailing conditions of temperature, pressure and relative humidity.

[0020] In some embodiments the dust handling compartment is configured to allow the handling of black mass, especially black mass dust which is produced in the recycling of battery materials, preferably in the recycling plant.

[0021] In some embodiments, the battery materials comprise at least one chosen from lithiated nickel cobalt manganese oxide, lithiated nickel cobalt aluminum oxide, lithium metal phosphate, lithium ion battery scrap, black mass derived from a lithium ion battery, and combinations thereof.

[0022] “Black mass” refers to materials derived from, for example, a lithium ion battery (e.g. used lithium ion batteries), lithium ion battery waste, lithium ion battery production scrap, lithium ion cell production scrap, lithium ion cathode active material, and / or combinations thereof by mechanical processes such as mechanical comminution. For example, black mass may be derived from battery scrap by mechanically treating the battery scrap to obtain the active components of the electrodes such as graphite and cathode active material and may include impurities from the casing, electrode foils, cables, separator, and electrolyte. In some examples, the battery scrap may be subjected to a heat treatment to pyrolyze organic (e.g., electrolyte) and polymeric (e.g., separator and binder) materials. Such a heat treatment may be performed before or after mechanical comminution of the battery material.

[0023] The black mass is usually provided in particulate form, i.e. , as a powder or dust before treatment in the dust handling compartment. The black mass may be provided in a storage container, e.g., a big bag. As black mass is hygroscopic, it is important that this powder does not come in contact with humidity to avoid any risk of clogging. Black mass dust is toxic and carcinogenic, and therefore it is imperative to prevent black mass dust from escaping into the environment and to prevent employees from getting into contact with black mass dust.

[0024] Black mass dust may comprise dust particles with an aerodynamic diameter xae< 10 micrometer (<10pm) (i.e. assuming a particle densitiy of 4g / cm3, this translates into a volume equivalent diameter (the volume equivalent diameter (xv) is the diameter for the sphere with the same volume as the particle under consideration) smaller than 5 micrometer (< 5 pm)). That means that the dust handling compartment is configured to allow the handling of dust with dust particles with an aerodynamic diameter xae< 10 micrometer (<10pm). It is also conceivable that battery materials other than black mass or black mass dust are treated in the dust handling compartment. In some embodiments, CAM (cathode active material) and MHP (mixed hydroxide precipitate) are also treated in the dust handling compartment.

[0025] In some embodiments, if the control module determines during control of the operating parameters that the operating parameters are outside a respective defined operating interval (whereby a defined operating interval is assigned to each operating parameter), the control module is designed to initiate an action to either regulate the operating parameters back into their respective defined operating range or to take another safety measure. Such an action can be, for example, direct regulation of the respective operating parameter, such as the pressure by a respective regulation system. For this purpose, the control module is connected to the respective regulation system wirelessly or wired. In some embodiments, in addition to the pressure prevailing in the dust handling compartment, a relative humidity within the dust handling compartment could also be monitored, i.e. controlled, as an additional operating parameter.

[0026] The pressure within the dust handling compartment is controlled to lie within a pregiven pressure range. The pressure within the dust handling compartment is controlled to be a negative pressure, i.e. a pressure that is less than atmospheric pressure, i.e. less than the ambient pressure outside the plant. The pressure within the dust handling compartment is controlled to lie within a range of 15 Pa (Pa = Pascal) to 50 Pa below atmospheric pressure, i.e. below the ambient pressure outside the plant. In some embodiments, the pressure within the dust handling compartment is controlled to lie within a range of 20 Pa to 40 Pa below atmospheric pressure. In some embodiments, the pressure within the dust handling compartment is controlled to lie within a range of 20 Pa to 30 Pa below atmospheric pressure. That means that a reduced pressure compared to the ambient pressure outside the plant is kept in the dust handling compartment. That means that the air pressure within the dust handling compartment is preferably kept 20 Pa to 30 Pa below ambient pressure outside the plant, so that no battery material dust, such as black mass dust can escape from the confined space, i.e. the dust handling compartment, to the environment in case of a leakage. In some embodiments, an alarm signal is issued if a pressure in the range of 5 Pa to 15 Pa below atmospheric pressure, e.g. of 10 Pa below atmospheric pressure, is reached or detected in the dust handling compartment. Such an alarm signal may initiate an action to either regulate the operating parameters back into their defined operating range or to take another safety measure. In other words, the control module is configured to control the pressure within the dust handling compartment to lie within a range of 15 Pa to 50 Pa below atmospheric pressure (i.e. ambient pressure), preferably within a range of 20 Pa to 40 Pa below atmospheric pressure, more preferably in a range of 20 Pa to 30 Pa below atmospheric pressure, and / or to issue an alarm signal if a pressure of 10 Pa is reached. When an alarm signal is emitted, it attracts people's attention. A responsible person can then decide how to proceed. For example, it can be decided which parts of the recycling plant in which the dust handling compartment is arranged are to be successively deactivated, e.g. turned off or decoupled from remaining parts of the recycling plant. As a rule, the entire recycling plant is not deactivated, e.g. turned off, but individual parts or components are turned off step by step. That means that, as a rule, only the smallest necessary number of components of the recycling plant is deactivated. This involves observing how the pressure inside the dust handling compartement behaves and whether further parts of the plant need to be inactivated, e.g. turned off. In some embodiments, the at least one material transfer device and, if available, the personnel sluice are closed as long as the pressure inside the dust handling device is outside the pregiven pressure range.

[0027] In some embodiments, the pressure inside the dust handling compartment is regulated with an air conditioning device. In this case the air conditioning system acts as pressure regulation system. Such an air conditioning device may comprise multiple components, such as an incoming air blower, an outgoing air blower, a filter, a device for humidity removal, and a damping unit. The pressure inside the dust handling compartement may be regulated as a difference pressure control compared to the surroundings. The pressure in the dust handling compartment can also be regulated separately from the air conditioning in the dust handling compartment.

[0028] In some embodiments, the plant comprises one or more pressure sensors to measure the pressure inside the dust handling compartment. In some embodiments, such a pressure sensor is integrated into the control module. In some embodiments, such a pressure sensor is separate from the control module and is connected to the control module for data transmission, so that pressure values measured by the pressure sensor can be transmitted to the control module either continuously, periodically or at random or defined intervals. These measured values are analysed by the control module and the control to be carried out by the control module is based, at least in part, on these measured values. Such a pressure sensor can be located inside the dust handling compartment.

[0029] Normally, the areas surrounding the dust handling compartment, including the processing compartment, are under atmospheric pressure. The slight underpressure within the dust handling compartment protects the environment, i.e. the surrounding areas of the dust handling compartment. As long as the slight underpressure is maintained, no dust particles, e.g. no black mass dusts can get outside, i.e. outside the dust handling compartment of the plant. In some embodiments, the processing compartment is also under slight negative pressure compared to the surroundings of the plant, although the pressure in the dust handling compartment is still lower than the pressure in the processing compartment. This means that the pressure drops from the processing compartment to the dust handling compartment, i.e. there is a downward pressure gradient from the surroundings of the plant to the processing compartment to the dust handling compartment.

[0030] In some embodiments, the relative air humidity within the dust handling compartment is also controlled. In some embodiments, the relative air humidity within the dust handling compartment is controlled to lie in a range of 45%relative humidity (RH) to 20%RH to prevent agglomeration of the black mass particles.

[0031] In some embodiments, the relative air humidity within the dust handling compartment is controlled to lie in a range of 40%RH to 25%RH. In some embodiments, the relative air humidity within the dust handling compartment is controlled to lie in a range of 40%RH to 30%RH. In other words, the control module is configured to control the relative air humidity within the dust handling compartment to lie in a range of 45%RH and 20%RH, preferably in a range of 40%RH to 25%RH, still more preferably in a range of 40%RH to 30%RH. The lower limit of 30%RH is within the range of acceptable working conditions according to which the relative air humidity should be in the range from about 30%RH to 60%RH.

[0032] The relative air humidity (RH - Relative Humidity) is a measure of the actual amount of water vapor in the air compared to the total amount of water vapor that can exist in the air at its current temperature and pressure. In other words, the relative air humidity describes the amount of water vapor present in air expressed as a percentage (%RH) of the amount needed to achieve saturation (of the air with water vapor) at the same temperature.

[0033] In some embodiments, the plant comprises one or more humidity sensors, i.e. hygrometers, to measure the relative humidity inside the dust handling compartment. In some embodiments, such a humidity sensor is integrated into the control module. In some embodiments, such a humidity sensor is separate from the control module and is connected to the control module for data transmission, so that relative humidity values measured by the humidity sensor can be transmitted to the control module either continuously, periodically or at random or defined intervals. These measured values are analysed by the control module and the control to be carried out by the control module is based, at least in part, on these measured values. Such a humidity sensor can be located inside the dust handling compartment.

[0034] A low relative air humidity, i.e. a relative air humidity in the above-mentioned range, has the effect that the free-flowing properties of the dust to be handled, e.g. the black mass dust is not affected. As soon as black mass becomes (too) moist, it sticks together and becomes hard, i.e. rock-hard lumps are formed. Such lumps are difficult to process further.

[0035] It is further envisaged that the dust handling compartment comprises an own air- conditioning system that is configured to provide an appropriate air conditioning in the dust handling compartment whereby both prescribed working conditions for persons working in the dust handling compartment and the defined operating parameters are complied with. The air-conditioning system may be realized as a combination of a cooling system and an air circulation system. The air- conditioning may act as regulation system for the relative air humidity inside the dust handling compartment. The air-conditioning may act as regulation system for the pressure inside the dust handling compartment.

[0036] In some embodiments, the dust handling compartment is configured to allow the handing of black mass dust which is produced in the recycling of battery materials in the recycling plant. Such black mass dust may be produced directly in the dust handling compartment and / or fed into the dust handling compartment via the at least one material transfer device and / or the at least one personnel sluice.

[0037] In some embodiments, each of the at least one material transfer device is chosen from the group comprising a material lock, a pipe, a funnel, a personnel sluice combined with a material lock and combinations thereof. The material transfer device can also be designed as a personnel sluice through which people as well as material can pass, i.e. can be transferred or transported.

[0038] In some embodiments, the device comprises multiple material transfer devices. Some of the multiple material transfer devices are configured to feed battery material, such as black mass into the dust handling compartment. Some of the multiple material transfer devices are configured to transport battery material, e.g. battery material treated in the dust handling compartment, from the inside of the dust handling compartment to the outside of the dust handling compartment, e.g. to the processing compartment of the recycling plant. The multiple material transfer devices can be designed identically or differently from one another. It is possible that at least one of the multiple material transfer devices is integrated into a personnel sluice or is a personnel sluice.

[0039] It is possible that the plant comprises different material transfer devices for different battery materials to be fed into or transport out of the dust handling compartment. That means each species of battery material which is to be treated or has been treated in the dust handling compartment is transferred through a material transfer device assigned to it.

[0040] In some further embodiments, the material transfer device, e.g. the material lock is configured to establish a pressure equalization, i.e. to allow controlled pressure transitions from the dust handling compartment to the processing compartment of the recycling plant and vice versa, when closing and opening to allow battery material to pass through when being transported between the dust handling compartment and the processing compartment. In some embodiments, a pressure cascade is created and / or maintained via the material transfer device, wherein the pressure decreases from the outside of the dust handling compartment to the inside of the dust handling compartment. In some embodiments, the material lock comprises and / or consists of two gates and an intermediate space that can be locked from the outside by the two gates. The gates may be realized as roller shutter doors, e.g. as pressure-resistant roller shutter doors. Alternative gate I door concepts are conceivable. In order to maintain the pressure gradient between the dust handling compartment and the processing compartment, the two gates cannot open or be opened simultaneously. The tightness of the material lock must be such that the air conditioning in the dust handling compartment and / or the intentionally generated pressure gradient from outside to inside of the dust handling compartment is maintained. The sealing of the material lock may be realized by common sealing materials, such as silicon. In some embodiments, a pressure difference between the intermediate space and the dust handling compartment is smaller or equal than 20 Pa. In some embodiments, a pressure difference between the intermediate space and the dust handling compartment is smaller or equal than 25 Pa. In some embodiments, a pressure difference between the intermediate space and the outside of the dust handling compartment is smaller or equal than 20 Pa. In some embodiments, a pressure difference between the intermediate space and the outside of the dust handling compartment is smaller or equal than 25 Pa. In some other embodiments, the at least one personnel sluice is configured to establish a pressure equalization, i.e. to allow controlled pressure transitions from the outside into the dust handling compartment and vice versa when a person is entering or leaving the dust handling compartment. In some embodiments, a pressure cascade is created and / or maintained via the personnel sluice, wherein the pressure decreases from the outside of the dust handling compartment to the inside of the dust handling compartment. In some embodiments, the personnel sluice comprises and / or consists of three adjoining and neighbouring rooms, wherein each room is accessible from outside the respective room through two doors. These two doors cannot be opened simultaneously in order to maintain the pressure gradient between the dust handling compartment and the processing compartment and / or between the dust handling compartment and the outside of the plant. One of the three rooms is located between the two other rooms and forms the centre room. A person coming from the processing compartment and / or from the outside of the plant and willing to enter the dust handling compartment must enter the first of the three rooms through a first of the two doors of the first room, the first door is then closed before the second of the two doors of the first room is opened and the person can enter the centre one of the three rooms through this second door of the first room. The second door of the first room is also the first door of the centre room. In the centre room the person can put on protecting clothes. Afterwards, the person can enter the third of the three rooms through the second door of the centre room. The second door of the centre room and the first door of the centre room cannot open or be opened simultaneously. The second door of the centre room corresponds to the first door of the third room. Finally, the person can enter the dust handling compartment via the second door of the third room which can only be opened when the first door of the third room is closed. The pressure gradient is maintained via this mechanism of three rooms. When leaving the dust handling compartment, the procedure is essentially the same in reverse order. However, in some embodiments, the person who intends to leave the dust handling compartment is subjected to a treatment of extracting harmful particles before leaving the dust handling compartment, i.e. the person is being thoroughly suctioned before leaving the dust handling compartment. Then, the person leaving the dust handling compartment and entering the third room remains in the third room and is flushed with air before entering the centre room. Thereby, the person remains in the third room until he is sufficiently flushed with air in order to eliminate or at least reduce contaminations on the person’s clothing. In some embodiments, "sufficiently flushed with air" means "flushed with air for a given time span, e.g. for 20 to 30 seconds. In another embodiment, the degree of contamination is measured and only when the degree of contamination is below a predefined threshold can the person go into the centre room. In another embodiment, the air volume is completely circulated according to the air capacity of the third room of the personnel sluice. This ensures that all air particles in the third room are exchanged. The person can take off the person’s protecting clothes in the centre room. The sealing of the personnel sluice may be realized by common sealing materials, such as silicon. Small battery material samples can also be transported into or from the dust handling compartment via the personnel sluice. In this case, it is possible that the third room which is next to the dust handling compartment has an additional door, i.e. a third door, through which the battery material samples can be introduced directly from the outside of the plant or from the processing compartment into the third room. From there, the battery material samples are then led through the second door of the third room into the dust handling compartment. The negative pressure is to be adapted such that the doors of the personnel sluice and / or the gates of the material lock can be opened on request. In some embodiments, a pressure difference between two adjacent rooms is smaller or equal than 15 Pa.

[0041] In further embodiments, the dust handling compartment comprises at least one air changing system, particularly at least one air filter system. This only takes place within the framework of legally defined regulations for the return of filtered air, comprising, for example, the interdiction to recycle any air contaminated with CMR substances (Carcinogenic, Mutagenic and toxic to Reproduction). Such regulations can be found, for example, in TRGS (Technische Regeln fur Gefahrstoffe). Such air changing system is used to exchange the air within the dust handling compartment and thereby clean the air within the dust handling compartment.

[0042] The dust handling compartment comprises at least one mixing tank, also called mixing vessel or mixing reactor. In some embodiments, the dust handling compartment comprises at least one conveyor, particularly a timed conveyor, a funnel and / or a srew comveyor to feed battery material, e.g. received via the at least one material transfer device, such as a material lock, into the at least one mixing tank. When providing black mass, particularly black mass dust as the battery material which is to be treated inside the dust handling compartment, the plant according to the invention is used in some embodiments as follows: the black mass dust, packed in a storage container, for example, in a big bag, is fed via the material lock from outside the dust handling compartment into the dust handling compartment. When using as conveyor a timed conveyor, a lance is inserted into the big bag and black mass is removed from the big bag with the lance and transferred with underpressure (with negative pressure) to a chamber above the mixing reactor. The chamber is also under negative pressure. Then the chamber is emptied into the mixing reactor. With the help of the lance, the black mass is sucked in via negative pressure (underpressure). Alternatively, the big bag can also be positioned above the mixing reactor and emptied into the mixing reactor via a funnel using gravity. In still another embodiment, a big bag is suspended above a funnel connected to the mixing vessel, the bottom of the big bag is cut open, and the black mass falls into the mixing vessel through the funnel. Alternatively, screw conveyors may also be used to transfer the particulate black mass from the big bag into the mixing vessel, i.e. to feed the black mass, i.e. the black mass dust into the mixing reactor. The step of conveying particulate black mass from the storage container into a mixing vessel is performed using suitable conveyors. In case of a bunker or a silo, direct conveying from the outside of the confined space, i.e. the dust handling compartment, through pipes or other powder conveying systems can be used, especially, when a continuous process is implemented. One example is the interconnection of two plants, e.g. a black mass production plant and a black mass refinery plant. The step of conveying particulate black mass, i.e. black mass dust, from the big bag or drum into a mixing vessel is performed using suitable powder conveyors present in the confined space (the dust handling compartment).

[0043] A big bag as packaging is well known in the art and it is an industrial container which is made of flexible fabric that is designed for storing and transporting dry and flowable products. Any other suitable packaging means can also be used.

[0044] In some embodiments, the conveyor means for safely conveying the particulate battery materials from the storage container into the mixing vessel in the dust handling compartment is abrasion-resistant coated. Since some type of black mass may be abrasive, it is important to ensure that the conveyor means are resistant thereto, at least at direct points of contact with the black mass. That means that in some embodiments, at least a part of an inner surface of the conveyor means, e.g. of a tunnel, a tube, a pipe, a funnel, a chute, a screw conveyor which may come or comes into contact with the particulate battery materials when the particulate battery materials pass the conveyor means, is coated with an abrasion-resistant coating. In some embodiments, the conveyor means are made, at least partially, of stainless steel. In some embodiments, the conveyor means comprise stainless steel pipes, stainless steel funnels. In some embodiments, at least a part of an inside of the conveyor means which may come or comes in contact with the particulate battery materials when the particulate battery materials are transported via the conveyor means into the mixing vessel, is coated with an abrasion-resistant coating I layer. Such coating may be one of the group comprising a high performance powder coating, HPPC, a high density two layer polyethylene coating, a fusion bonded epoxy powder coating, FBE, a coating created by galvanizing. In some embodiments, at least a part of the inside of the conveyor means is lined with a ceramic material. In some embodiments, the conveyor means includes stainless steel pipes, some of which are straight and some of which are curved I bent wherein at least in the bends, the pipes are lined with a ceramic material. When the particulate battery material is transported through a pipe in a gas flow, the gas flow keeps the particulate battery material essentially in the centre of the gas flow when passing straight parts of the respective pipe, so that the particulate battery comes in contact with the inner surface of the pipe only in the bends of the pipe, but not or only a little along the straight parts of the pipe.

[0045] The mixing reactor is configured to produce a slurry, e.g. a suspension, from the black mass dust fed to the mixing reactor and further added liquid, e.g. water. The production of a slurry eliminates or at least reduces the danger of inhalation of toxic substances, i.e. black mass dusts, by persons involved in further processing of the black mass. Treating battery material dusts in the dust handling compartment comprises the production of a suspension from the battery material dust fed to the mixing reactor and further added liquid, e.g. water.

[0046] The plant further comprises transport means, i.e. conveyor means, such as a pump system, which is configured to transport battery material treated in the dust handling compartment, such as the produced slurry, from the dust handling compartment via the at least one material transfer device, e.g. a material lock to the outside of the dust handling compartment, i.e. to the processing compartment of the plant.

[0047] In some embodiments, the dust handling compartment comprises at least one of a glove box, an analytical device and a filter press. The analytical device may be chosen from the group comprising an XRF (X-Ray Fluorescence) device, a pressure nutsch, PXRD (Powder X-Ray Diffraction) device, LIBS (Laser Induced Breakdown Spectroscopy) device, a pycnometer, a UV / VIS spectrometer, a particle size measuring instrument. The pressure nutsch is configured to determine properties of a filter cake for a filter press. The pressure nutsch is used for filtrations for which the filter press is used. A slurry composed of a mixture of a precipitate and a mother lye is inserted in the pressure nutsch and a pressure is built up and a filtration is performed under pressure. A height of a resulting filter cake is determined in order to determine a number of chambers of the filter press which is to be used to sufficiently separate the solid and the liquid phase of the filter cake. The PXRD device and / or the LIBS device are configured to be used for powder anaylsis. The pycnometer is configured to be used for density measurements. The analytical devices that can be placed in the dust handling compartment are not limited to those listed above. The analytical devices are used to analyse battery materials inside the dust handling compartment.

[0048] Still another aspect of the invention is a method for the safe handling of battery material dust, such as black mass dust, generated during a recycling process of battery materials, wherein the method is carried out using a plant as described herein and the method comprises at least the following steps: providing the battery material dust, e.g. the black mass dust, in the dust handling compartment, wherein the battery material dust, e.g. the black mass dust, may be fed into the dust handling compartment via the at least one material transfer device and / or via a personnel sluice, and / or produced directly in the dust handling compartment, controlling, using the control module, a pressure within the dust handling compartment to lie within a range of 15 Pa to 50 Pa below atmospheric pressure, preferably within a range of 20 Pa to 40 Pa below atmospheric pressure, still more preferably within a range of 20 Pa to 30 Pa, and optionally controlling, using the control module, a relative air humidity within the dust handling compartment to lie within a range of 45%RH to 20%RH, preferably in a range of 40%RH to 25%RH, more preferably in a range of 40%RH to 30%RH, to prevent agglomeration of the battery material particles, e.g. the black mass particles,. preparing a slurry, i.e. a suspension, from the provided battery material dust, e.g. the provided black mass dust, and an added liquid, the added liquid may be water in the at least one mixing vessel, transporting the slurry via the material transfer device from the dust handling compartment to the processing compartment for further processing.

[0049] In some embodiments, preparing a slurry from the provided battery material dust, e.g. the provided black mass dust, and an added liquid comprises mixing the provided battery material dust, e.g. the provided black mass dust, and water in a mixing vessel with stirring to produce an aqueous suspension of battery material particles, e.g. of black mass particles.

[0050] In some embodiments of the proposed method, feeding the battery material dust, e.g. the the black mass dust into the dust handling compartment comprises transporting a big bag of battery material dust, e.g. of black mass dust via the at least one material transfer device, such as a material lock. The at least one material transfer device, e.g. a material lock is configured to allow controlled pressure transitions from the outside into the dust handling compartment. In some embodiments, the material lock comprises and / or consists of two gates and an intermediate space that can be locked from the outside by the two gates. The gates may be realized as roller shutter doors, e.g. as pressure-resistant roller shutter doors. Alternative gate I door concepts are conceivable. The tightness of the material lock must be such that the air conditioning in the dust handling compartment and / or the intentionally generated pressure gradient from outside to inside of the dust handling compartment is maintained. The sealing of the material lock may be realized by common sealing materials, such as silicon. The two gates can only be opened and closed with a time delay so that both gates are never open at the same time. Only in an emergency case, the two gates can be opened or closed simultaneously.

[0051] The black mass is usually in powder form, also called black mass dust herein, before treatment in the dust handling compartment. The black mass may include also pyrolyzed black mass. The black mass dust, packed in big bags, is transported via the material lock (as material transfer device) from outside into the dust handling compartment. The dust handling compartment comprises at least one mixing tank. In some embodiments, the dust handling compartment comprises at least one conveyor, particularly a timed conveyor, and / or a funnel to feed the black mass dust received via the at least one material lock into the at least one mixing tank. When using a timed conveyor, a lance is inserted into the big bag and black mass dust is removed from the big bag with the lance and transferred with underpressure (with negative pressure) to a chamber above the mixing tank. The chamber is also under negative pressure. Then the chamber is emptied into the mixing tank. With the help of the lance, the black mass dust is sucked in via negative pressure (underpressure). Alternatively, the big bag can also be positioned above the mixing tank and emptied into the mixing tank via a funnel using gravity. Alternatively, screw conveyors may also be used to feed the black mass dust into the mixing tank.

[0052] In some embodiments, the method involves providing particulate black mass in a storage container, e.g., a big bag, placed within the confined space (i.e. the dust handling compartment) featuring a controlled atmosphere, conveying particulate black mass (black mass dust) from the storage container into the mixing vessel located within the confined space, mixing the black mass and water in the mixing vessel with stirring to produce an aqueous suspension of black mass particles, transferring the suspension into one or more storage tanks, and continuously keeping the suspension in motion in the storage tank(s) by stirring and / or recirculation using a suitable pump system. The one or more storage tanks may be located in the dust handling compartment and transported to the processing compartment for further processing. Alternatively, the one or more storage containers are located outside the dust handling compartment and the suspension, i.e. the slurry is pumped, using the pump system, from the mixing vessel located in the dust handling compartment directly via the material transfer device into the one or more storage tanks located in the processing compartment. For recovering valuable metals, the suspension is removed from the storage tank and dosed into a leaching reactor located in the processing compartment, optionally mixed with cathode active material (CAM) and / or mixed metal hydroxide precipitate (MHP) and subjected to hydrometallurgical treatment.

[0053] In some embodiments, the method further comprises analyzing the black mass in the dust handling compartment using at least one analytical device installed in the dust handling compartment, the at least one analytical device being one of the group comprising an XRF-device, a pressure nutsch, pXRD device, LIBS device, a pycnometer, a UV / VIS spectrometer, a particle size measuring instrument.

[0054] In some further embodiments, the method further comprises feeding contaminated objects into the dust handling compartment via the at least one material transfer device, e.g. a material lock, and / or at least one personnel sluice and purifying the contaminated objects in a glove box which is installed within the dust handling compartment.

[0055] It is to be understood that with regard to method-related definitions of terms and the effects and advantages of method-related features, full reference can be made to the disclosure of analogous definitions, effects and advantages of the plant according to the invention and vice versa. A repetition of explanations of analogous features, their effects and advantages can thus be dispensed with in favor of a more compact description, without such omissions having to be interpreted as a limitation for one of the disclosed objects of the invention.

[0056] It should be noted that the features listed individually in the claims can be combined with each other in any technically meaningful way, even across category boundaries, e.g. between device, plant and method, without leaving the scope of the invention.

[0057] It is an essential advantage of the device, the plant and the method according to the invention, that battery material dusts, e.g. black mass dusts can be easily treated without allowing harmful dust particles to reach outside the dust handling compartment, i.e. no respirable dust particles are set free (i.e. reach outside the dust handling compartment) when battery material dust, e.g. black mass dust is treated in the dust handling compartment. It is possible that the processing compartment of the recycling plant is an essentially dust-free area or at least only powders are processed in the processing compartment whose particle sizes are not potentially dangerous to human health, e.g. powders with particles with an aerodynamic diameter xae> 10 micrometer (>10pm). Assumng a particle density of 4 g / cm3this translates into a volume equivalent diameter xv> 5pm.

[0058] In some embodiments the dust handling compartment is configured to allow the handling of battery material dust, e.g. black mass dust which is produced in the recycling of battery materials in the recycling plant. Black mass dust may comprise dust particles with a volume equivalent diameter xvsmaller than 5 micrometers (< 5 pm) assuming a particle density of 4g / cm3. Such dust particles are considered to be dangerous for humans since these dust particles are respirable. That means that the dust handling compartment is configured to allow the handling of dust with dust particles of a volume equivalent diameter xvsmaller than 5 mcirometer (assuming a particle density of 4g / cm3). Acting shear forces can augment the release of respirable dust particles. It is also conceivable that battery materials other than black mass or black mass dust are treated in the dust handling compartment. In some embodiments, CAM (cathode active material) and MHP (mixed hydroxide precipitate) are also treated in the dust handling compartment.

[0059] It shall be understood that the features described previously and to be described subsequently may be used not only in the indicated combinations but also in different combinations or on their own without leaving the scope of the present invention.

[0060] The invention is described in detail by means of an exemplary embodiment and with reference to the drawings. Like components are indicated by like reference numerals throughout the drawings.

[0061] Brief description of the drawings

[0062] Fig. 1 schematically shows an entity diagram of a plant according to the invention Detailed description of the drawings

[0063] Figure 1 shows a device 100 which is arranged and used in a recycling plant 200 for recycling battery materials. The plant 200 comprises a processing compartment 201 and the device 100. The device 100 and thus the plant 200 comprises a dust handling compartment 101 , also referred to as a black area, at least one material transfer device, such as a material lock 102, and at least one personnel sluice 103, wherein the dust handling compartment 101 is structurally separated from and gas-tight lockable and sealed against the processing compartment 201 of the recycling plant 200. The dust handling compartment 101 and the processing compartment 201 are connected and accessible to each other via the at least one material lock 102 and the at least one personnel sluice 103. The dust handling compartment 101 can also be accessed directly from outside the plant 200 via at least one personnel sluice (not shown in Figure 1 ). The device 100 and thus the plant 200 further comprises at least one control module 104 which is configured to control operating parameters of the dust handling compartment 101 , wherein as such operating parameters at least a pressure within the dust handling compartment 101 is to be controlled or is controlled. In some embodiments, as a further operative paramenter, a relative air humidity within the dust handling compartment 101 is also to be controlled or is also controlled.

[0064] The material lock 102 is configured to allow controlled pressure transitions from the dust handling compartment 101 to the processing compartment 201 and vice versa, when closing and opening, to allow battery material to pass through when being transported between the dust handling compartment 101 and the processing compartment 201. The material lock 102 comprises and / or consists of two gates 111 , 113 and an intermediate space 112 that can be locked from the outside by the two gates 111 , 113. The gates 111 , 113 may be realized as roller shutter doors, e.g. as pressure-resistant roller shutter doors. The two gates 111 , 113 both open inwards towards the intermediate space 112. Alternative gate / door concepts are conceivable. When the plant 200 is in operation, there is a pressure gradient between the dust handling compartment 101 and the processing compartment 201 . Such pressure gradient is in the range of 5 Pa to 50 Pa, preferably in the range from 10 Pa to 30 Pa, still more preferably in the range from 15 Pa to 30 Pa, wherein the pressure within the processing compartment 201 is always greater than the pressure within the dust handling compartment 101. In some embodiments, both the dust handling compartment 101 and the processing compartment 201 are under a negative pressure, i.e. a pressure below the ambient pressure outside the plant 200. In order to maintain the pressure gradient between the dust handling compartment 101 and the processing compartment 201 , the two gates 111 , 113 cannot open or be opened simultaneously. The tightness of the material lock 102 must be such that the air conditioning in the dust handling compartment 101 and / or the intentionally generated pressure gradient from outside to inside of the dust handling compartment 101 is maintained. The sealing of the material lock 102 may be realized by common sealing materials, such as silicon.

[0065] The personnel sluice 103 is configured to allow controlled pressure transitions from the outside into the dust handling compartment 101 and vice versa when a person is entering or leaving the dust handling compartment 101. The personnel sluice 103 comprises and / or consists of three adjoining and neighbouring rooms 130, 140, 150, wherein each room 130, 140, 150 is accessible from outside the respective room through two doors 131 , 132 and 141 , 142 and 151 , 152. These two doors 131 , 132 and 141 , 142 and 151 , 152 cannot be opened simultaneously in order to maintain the pressure gradient between the dust handling compartment 101 and the processing compartment 201. One 140 of the three rooms 130, 140, 150 is located between the two other rooms 130, 150 and forms the centre room 140. A person coming from the processing compartment 201 and willing to enter the dust handling compartment 101 has to enter the first 130 of the three rooms 130, 140, 150 through a first 131 of the two doors 131 , 132 of the first room 130, the first door 131 is then closed before the second 132 of the two doors of the first room 130 is opened and the person can enter the centre 140 one of the three rooms through this second door 132 of the first room 130. The second door 132 of the first room 130 is also the first door 141 of the centre room 140. In the centre room 140 the person can put on protecting clothes. Afterwards, the person can enter the third 150 of the three rooms through the second door 142 of the centre room 140. The second door 142 of the centre room 140 and the first door 141 of the centre room 140 cannot open or be opened simultaneously. The second door 142 of the centre room 140 corresponds to the first door 151 of the third room 150. Finally, the person can enter the dust handling compartment 101 via the second door 152 of the third room 150 which can only be opened when the first door 151 of the third room 150 is closed. The pressure gradient is maintained via this mechanism of three rooms 130, 140, 150. When leaving the dust handling compartment 101 , the procedure is essentially the same in reverse order. However, in some embodiments, the person who intends to leave the dust handling compartment 101 is subjected to a treatment of extracting harmful particles before leaving the dust handling compartment 101 , i.e. the person is being thoroughly suctioned before leaving the dust handling compartment 101. Then, the person leaving the dust handling compartment 101 and entering the third room 150 remains in the third room 150 before entering the centre room 140 until the person is sufficiently flushed with air in order to eliminate or at least reduce contaminations on the person’s clothing. The degree of contamination may be measured and only when the degree of contamination is below a predefined threshold the person can go into the centre room 140. In another embodiment, the air volume can be completely circulated according to the air capacity of the third room 150 of the personnel sluice 103. This ensures that all air particles in the third room 150 are exchanged. The person can take off the person’s protecting clothes in the centre room 140. The sealing of the personnel sluice 102 may be realized by common sealing materials, such as silicon. Small battery material samples can also be transported into or from the dust handling compartment 101 via the personnel sluice 103. The doors 131 , 132 of the first room 130 both open inwards towards the first room 130. The doors 151 , 152 of the third room 150 both open inwards towards the third room 150. The dust handling compartment 101 and thus the plant comprises at least one mixing tank (not shown in figure 1 ) and at least one conveyor (not shown in figure 1 ), particularly a timed conveyor, and / or a funnel to feed battery material received via the at least one material lock 102 into the at least one mixing tank. When providing black mass, particularly black mass dust as the battery material which is to be handled inside the dust handling compartment 101 , the plant 200 according to the invention is used as follows: the black mass dust, packed in big bags, is fed via the material lock 102 from outside the dust handling compartment 101 into the dust handling compartment 101. When using as conveyor a timed conveyor, a lance is inserted into the big bag and black mass is removed from the big bag with the lance and transferred with underpressure (with negative pressure) to a chamber above the mixing reactor. The chamber is also under negative pressure. Then the chamber is emptied into the mixing reactor. With the help of the lance, the black mass is sucked in via negative pressure (underpressure). Alternatively, the big bag can also be positioned above the mixing reactor and emptied into the mixing reactor via a funnel using gravity. Alternatively, screw conveyors may also be used to feed the black mass into the mixing reactor.

[0066] The mixing reactor is configured to produce a slurry, e.g. a suspension, from the black mass dust fed to the mixing reactor and further added liquid, e.g. water. The production of a slurry eliminates or at least reduces the danger of inhalation of toxic substances, i.e. black mass dusts, by persons involved in further processing of the black mass.

[0067] Battery materials other than black mass or black mass dust can also be treated in the dust handling compartment 101. As such, for instance, CAM (cathode active material) and MHP (mixed hydroxide precipitate) can also be treated in the dust handling compartment 101 . The device and thus the plant further comprise transport means I conveyor means (not shown in figure 1 ) for transferring the treated battery material dust, e.g. the produced slurry, via the at least one material transfer device 102 from the dust handling compartment to the processing compartment 201 for further processing. Such transport means can be a pump system.

[0068] The dust handling compartment 101 can further comprise at least one of a glove box, an analytical device and a filter press. The analytical device may be chosen from the group comprising an XRF (X-Ray Fluorescence) device, a pressure nutsch, PXRD (Powder X-Ray Diffraction) device, LIBS (Laser Induced Breakdown Spectroscopy) device, a pycnometer. Such an analytical device is used to analyze battery materials inside the dust handling compartment 101 .

[0069] List of reference numerals

[0070] 100 device

[0071] 101 dust handling compartment

[0072] 102 material lock 103 personnel sluice

[0073] 104 control module

[0074] 111 gate

[0075] 112 intermediate space

[0076] 113 gate 130 first room

[0077] 131 , 132 door

[0078] 140 centre room

[0079] 141 , 142 door

[0080] 150 third room 151 , 152 door

[0081] 200 recycling plant

[0082] 201 processing compartment

[0083] 202 material lock

Claims

BASF SE B25.179P-WO67056 Ludwigshafen am Rhein 25.09.2025 / lg / jlClaims1 . A plant (200) for recycling battery materials wherein the plant (200) comprises a processing compartment (201 ) and a dust handling compartment (101 ) and at least one material transfer device (102), wherein the dust handling compartment (101 ) is a confined space and is structurally separated from the processing compartment (201 ), wherein the dust handling compartment (101 ) and the processing compartment (201 ) are connected and accessible to each other via the at least one material transfer device (102), wherein the at least one material transfer device (102) is configured to allow controlled pressure transitions from the dust handling compartment (101 ) to the outside of the dust handling compartment (101 ) and vice versa, when opening and closing, wherein the plant further comprises at least one control module (104) which is configured to control operating parameters of the dust handling compartment (101 ), wherein as such operating parameters at least a pressure within the dust handling compartment (101 ) is controlled, wherein the pressure within the dust handling compartment (101 ) is controlled to lie within a range of 15 Pa to 50 Pa below the ambient pressure outside the plant wherein the plant comprises at least one mixing vessel in the dust handling compartment (101 ) to treat battery material dust produced during a recycling process by preparing a slurry from the battery material dust and a liquid, and conveyor means for transferring the treated battery material dust via the at least one material transfer device (102) from the dust handling compartment to the processing compartment (201 ) for further processing.

2. The plant according to claim 1 wherein the plant further comprises at least one personnel sluice (103), the at least one personnel sluice (103) being configured to allow controlled pressure transitions from the dust handling compartment (101 ) to the outside of the dust handling compartment (101 ) and vice versa when opening and closing.

3. The plant according to any one of claims 1 or 2, wherein the at least one material transfer device (102) is chosen from the group comprising a material lock (102), a pipe, a funnel, a personnel sluice combined with a material lock and combinations thereof.

4. The plant according to one of claims 1 to 3 wherein the dust handling compartment (101 ) comprises at least one air changing system, particularly at least one air filter system.

5. The plant according to one of claims 1 to 4 wherein the dust handling compartment (101 ) comprises conveyor means for safely conveying battery material dust from a storage container placed in the dust handling compartment into the at least one mixing vessel, the conveyor means being chosen from the group comprising a timed conveyor with a suction lance, a pneumatic transfer cyclone with a suction lance, a screw conveyor, a pipe connected to the mixing vessel, a funnel connected to the mixing vessel and combinations thereof.

6. The plant according to claim 5, wherein the suction lance is configured to pierce a big bag used as the storage container, or to be inserted into an opened drum used as the storage container, and to suck in battery material dust from the storage container and fill a chamber placed above the mixing vessel, the chamber being configured to be emptied into the mixing vessel using gravity.

7. The plant according to one of claims 1 to 6 wherein the dust handling compartment (101 ) comprises a glove box for purifying contaminatedobjects which have been fed into the dust handling compartment via the at least one material transfer device (102) and / or at least one personnel sluice (103).

8. The plant according to one of claims 1 to 7 wherein the dust handling compartment (101 ) comprises at least one of a filter press and an analytical device, such as an XRF-device, a pressure nutsch, a pXRD device, a LIBS device, a pycnometer, a UV / VIS spectrometer, a particle size measuring instrument.

9. A method for the safe handling of battery material dust generated during a recycling process of battery materials, wherein the method is carried out using a plant according to one of claims 1 to 8 and the method comprises at least the following steps:- providing the battery material dust within the dust handling compartment (101 ),- controlling, using the control module (104), a pressure within the dust handling compartment (101 ) to lie within a range of 15 Pa to 50 Pa below the ambient pressure outside the plant, preferably in a range of 20 Pa to 30 Pa below the ambient pressure outside the plant,- preparing a slurry from the battery material dust and a liquid in the at least one mixing vessel,- transporting the slurry via the at least one material transfer device (102) and / or a personnel sluice (103) from the dust handling compartment (101 ) to the processing compartment (201 ) for further processing.

10. The method according to claim 9, wherein the method further comprises analyzing the battery material dust in the dust handling compartment (101 ) using at least one analytical device installed in the dust handling compartment, the at least one analytical device being one of the group comprising an XRF-device, a pressure nutsch, apXRD device, a LIBS device, a pycnometer, a UV / VIS spectrometer, a particle size measuring instrument.

11. The method according to claim 9 or 10, wherein the method further comprises feeding contaminated objects into the dust handling compartment (101 ) via the at least one material transfer device (102) and / or at least one personnel sluice (103) and purifying the contaminated objects in a glove box which is installed within the dust handling compartment (101 ).

12. The method according to one of claims 9 to 11 , wherein the step of providing battery material dust comprises conveying, using conveyor means, the battery material dust from a storage container placed in the dust handling compartment into the at least mixing vessel, the conveyor means being chosen from the group comprising a timed conveyor with a suction lance, a pneumatic transfer cyclone with a suction lance, a screw conveyor, a pipe connected to the mixing vessel, a funnel connected to the mixing vessel and combinations thereof.

13. The method according to claim 12, wherein when using as conveyor means a timed conveyor with a suction lance or a pneumatic transfer cyclone with a suction lance, the suction lance is inserted into the storage container and battery material dust is sucked in from the storage container with the suction lance and transferred to a chamber above the mixing vessel, wherein the chamber is emptied into the mixing vessel using gravity.

14. The method according to claim 12, wherein the storage container, such as a big bag, is suspended above a funnel connected to the mixing vessel, the bottom of the storage container is cut open, and the battery material dust falls into the mixing vessel through the funnel using gravity.

15. The method according to one of claims 9 to 11 , wherein the step of providing the battery material dust within the dust handling compartment (101 ) comprises conveying the battery material dust from a storage container placed outside the dust handling compartment, such as a silo or a bunker, directly into the mixing vessel through a pipe connected to the mixing vessel.

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