Method for processing spent material related to direct electric power generation and storage using UV-c functionalized catalysts

Abstract

A method for processing spent material related to direct electric power generation and storage is provided. The spent material related to direct electric power generation and storage comprises a metal component bonded to a carbon component and / or a second metal component. A catalyst is suspended in an aqueous acidic medium or de-ionized water to form a catalyst slurry. The catalyst slurry is UV-C functionalized. Using the UV-C functionalized catalyst the metal component is separated from the carbon component and / or second metal component. A dry process comprises drying the UV-C functionalized catalyst slurry to form a UV-C functionalized catalyst paste. The UV-C functionalized catalyst paste is dispersed on a surface of the carbon component and / or second metal component of the spent material related to direct electric power generation and storage when the spent material is in un-shredded form or mixed with the spent material related to direct electric power generation and storage when the spent material is in shredded form. A wet process comprises immersing the spent material related to direct electric power generation and storage in the catalyst slurry.

Description

[0001] METHOD FOR PROCESSING SPENT MATERIAL RELATED TO DIRECT ELECTRIC POWER GENERATION AND STORAGE USING UV-C FUNCTIONALIZED CATALYSTS

[0002] FIELD

[0003] The present application relates to the field of spent power generation and storage material recycling and, more particularly, to a method for processing spent material related to direct electric power generation and storage comprising a metal component bonded to a second metal component and / or a metal component bonded to a carbon component by separating the metal component from the carbon component and / or second metal component using UV-C functionalized catalysts for breaking down of the binder such as, for example, one or more polymers, polyfluoric compounds, or cellulose binders with a co-polymer.

[0004] BACKGROUND

[0005] In the past decades, Lithium-Ion Batteries (LIBs) have been widely utilized in various applications such as consumer electronics because of their superior energy density, long life and discharging capability. LIBs generally include an anode, an electrolyte, and a cathode that contains lithium in the form of a lithium-transition metal oxide. In recent years, LIBs are being used in significant quantities for automotive propulsion because these batteries can provide many years of reliable service and are expected to last for about 10 years under normal driving conditions. LIBs may subsequently be used for utility energy storage and are eventually considered to have reached the end of their useful life.

[0006] Environmental issues of spent LIBs have attracted widespread concern in the public. If reusable materials can be recovered from used batteries, less raw materials will be needed to be extracted from the limited supplies in the ground. In addition, significant negative environmental impacts caused by mining and processing ores (e.g., SOx emissions from smelting of sulfide ores, such as those that yield copper, nickel, and cobalt) may be reduced or avoided if the used LIBs can be recycled.

[0007] Unfortunately, less than 5% of spent LIBs are recycled, and most of the un-recycled LIBs end up in landfills.A major problem of LIB recycling is the separation of the current collector material component (typically consisting of aluminum or copper foil) from the carbon material component or carbon bound domain, which can include charged carbon such as acetylene black, nickel, cobalt manganese, and lithium, and are firmly bonded with an adhesive (binder), which is typically Poly vinylidene Fluoride (PVDF) or, for example, one or more polymers, polyfluoric compounds, or cellulose binders with co-polymer, to form the LIB electrodes. Firm adhesion is obtained by inducing structural changes in the material using thermochemical treatment (calendaring). Calendaring of electrodes enhances electrode energy density and improves electronic conductivity and is performed on all commercial electrodes. Primo, Emiliano N., et al. “Understanding the Calendering Processability of Li(Ni0.33Mn0.33Co0.33)02-Based Cathodes.” Journal of Power Sources, vol. 488, Mar.

[0008] 2021, p. 229361.

[0009] During manufacture of the LIB electrodes, two concerns arise:

[0010] • the thermochemical bonds between the current collector material components and the carbon material components; and,

[0011] • the percolation pathway for lithium-ion transport through the carbon material component,

[0012] causing large quantities of LIB electrode waste material, referred to as scraps, being generated during LIB electrode production that do not meet specification, thus substantially increasing the amount of LIB material disposed of in landfills. Also, batteries that reach end of life are either separated for electrodes or ground into powders to generate a black mass.

[0013] Currently employed LIB recycling technologies are based on pyrometallurgy or hydrometallurgy -pyrometallurgy processes for processing of electrode scraps (direct recycling) or processing black mass. Further processes have been proposed in:

[0014] Harper, Gavin, et al. “Recycling Lithium-Ion Batteries from Electric Vehicles.” Nature, vol. 575, no. 7781, 6 Nov. 2019, pp. 75-86;

[0015] Yu, Xiaolu, et al. “Current Challenges in Efficient Lithium-Ion Batteries’ Recycling: A Perspective.” Global Challenges, vol. 6, no. 12, 8 Sept. 2022, p. 2200099;

[0016] Ma, Xiaotu, et al. “Li-Ion Battery Recycling Challenges.” Chem, vol. 7, no. 11, Nov.

[0017] 2021, pp. 2843-2847;Ji, Guanjun, et al. “Direct Regeneration of Degraded Lithium-Ion Battery Cathodes with a Multifunctional Organic Lithium Salt.” Nature Communications, vol. 14, no. 1, 3 Feb. 2023, p. 584;

[0018] Yang, Tingzhou, et al. “Sustainable Regeneration of Spent Cathodes for Lithium-Ion and Post-Lithium-ion Batteries.” Nature Sustainability, 14 May 2024, pp. 1-10;

[0019] Wang, Xu, et al. “Recycling the Cathode Scrap of Spent Lithium-Ion Batteries as an Easily Recoverable Peroxymonosulfate Catalyst with Enhanced Catalytic Performance.” A CS Sustainable Chemistry & Engineering, vol. 8, no. 30, 15 July 2020, pp. 11337-11347;

[0020] Mirza, Mateen, et al. “Electrochemical Recovery of Lithium-Ion Battery Materials from Molten Salts by Microstructural Characterization Using X-Ray Imaging.” Cell Reports Physical Science, vol. 4, no. 4, 19 Apr. 2023, p. 101333;

[0021] Dolotko, Oleksandr, et al. “Universal and Efficient Extraction of Lithium for Lithium- Ion Battery Recycling Using Mechanochemistry.” Communications Chemistry, vol. 6, no. 1, 28 Mar. 2023, pp. 1-8;

[0022] Bai, Yaocai, et al. “Sustainable recycling of Cathode Scraps via Cyrene-Based Separation.” Sustainable Materials and Technologies , vol. 25, 1 Sept. 2020, pp. e00202-e00202;

[0023] Jena, Kishore K., and Daniel S. Choi. “Recycling of Cathode Active Materials from Spent Lithium-Ion Batteries (LIBs): Effective Methodology for Environmental Remediation.” Materials Chemistry and Physics , vol. 311, 1 Jan. 2024, p. 128532; and,

[0024] Ji, Yi, et al. “Direct Recycling Technologies of Cathode in Spent Lithium-Ion Batteries.” Clean Technologies and Recycling, vol. 1, no. 2, 2021, pp. 124-151.

[0025] Unfortunately, all these processes have various drawbacks preventing the same from being widely implemented for LIB recycling such as:

[0026] • complexity;

[0027] • requiring high processing temperatures;

[0028] • requiring large quantities of solvents or acids; and,

[0029] • requiring separation and purification steps for extracting material from leach solutions.

[0030] Similar problems also arise when recycling photovoltaic or fuel cell waste materials.There is a need for a method for separating a metal component from a carbon component and / or from a second metal component of spent material related to direct electric power generation and storage that is simple, and does not require large quantities of solvents or acids. There is also a need for a method that enables separating at room temperature. There is further a need for a method that enables re-using of the materials employed for separating the metal component from the carbon component and / or second metal component. This applies to black mass as well.

[0031] This background information is provided for making information believed by the applicant to be of possible relevance to the present application. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the subject matter presented herein.

[0032] SUMMARY

[0033] An aspect of the present application is to provide a method for processing spent material related to direct electric power generation and storage comprising a metal component bonded to a carbon component and / or a second metal component that employs a UV-C functionalized catalyst to induce shifting within the carbon component and / or second metal component, and enable increased percolation through the carbon component and / or second metal component, consequently causing the metal component to dissociate from the carbon component and / or second metal component. The method:

[0034] • is simple;

[0035] • does not require large quantities of solvents or acids; and,

[0036] • is performed at room temperature.

[0037] Another aspect of the present application is to provide a method that enables re-using of the materials employed for separating the metal component from the carbon component and / or second metal component.

[0038] In accordance with one aspect, the present application provides a method for processing spent material related to direct electric power generation and storage. The spent material related to direct electric power generation and storage comprises a metal component bonded to a carboncomponent and / or a second metal component. A catalyst is suspended in an aqueous acidic medium or de-ionized water to form a catalyst slurry. The catalyst slurry is then UV-C functionalized. Using the UV-C functionalized catalyst, the metal component is separated from the carbon component and / or second metal component.

[0039] The UV-C functionalization and the separation are performed in at least an enclosure having the catalyst and at least a UV-C radiation source disposed therein. The enclosure is adapted for blocking visible radiation. An inside surface of the enclosure is capable of reflecting the UV-C radiation such that at least a portion of the UV-C radiation is reflected onto at least a portion of the catalyst.

[0040] In one embodiment, the present application further provides a dry process comprising drying the UV-C functionalized catalyst slurry to form a UV-C functionalized catalyst paste.

[0041] The UV-C functionalized catalyst paste is dispersed on a surface of the carbon component and / or second metal component of the spent material related to direct electric power generation and storage when the spent material is in un-shredded form or mixed with the spent material when the spent material is in shredded form. The separated spent material components are washed in water for removing the catalyst from the separated spent material components.

[0042] In another embodiment, the present application further provides a wet process comprising immersing the spent material related to direct electric power generation and storage in the catalyst slurry. After separation, the catalyst slurry is removed from the separated spent material components.

[0043] The present application provides the dry process with the step of drying the water with the catalyst to form a catalyst paste for re-use. The present application also provides the wet process with the step of re-using the catalyst slurry that has been removed from the separated spent components.

[0044] In another embodiment, black mass or shredded batteries are treated in water with UV-C to release the current collector material by breaking the PVDF bonds.BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Drawings of embodiments are provided herewith and briefly described as follows:

[0046] Figure 1 is a flow diagram of a dry process of a method for processing spent material related to direct electric power generation and storage described herein;

[0047] Figure 2 is a schematic diagram of a system for performing the dry process of the method for processing spent material related to direct electric power generation and storage described herein;

[0048] Figure 3 is a flow diagram of a wet process of a method for processing spent material related to direct electric power generation and storage described herein;

[0049] Figure 4 is a schematic diagram of a system for performing the wet process of the method for processing spent material related to direct electric power generation and storage described herein;

[0050] Figure 5 is a schematic diagram of a bench scale experimental setup for performing the wet process of the method for processing spent material related to direct electric power generation and storage described herein;

[0051] Figure 6 is a schematic diagram illustrating separated spent material components related to direct electric power generation and storage obtained in the bench scale experiment; and, Figures 7 to 26 are schematic diagrams illustrating measured results of the bench scale experiment.

[0052] DETAILED DESCRIPTION

[0053] Disclosed herein is a method for processing spent material related to direct electric power generation and storage. The spent material related to direct electric power generation and storage comprises a metal component bonded to a carbon component and / or a second metal component. A catalyst is suspended in an aqueous acidic medium or de-ionized water to form a catalyst slurry. The catalyst slurry is UV-C functionalized using a UV-C radiation source disposed in a dark enclosure. After the UV-C functionalization, the catalyst is used for separating the metal component from the carbon component and / or second metal component using a dry process or a wet process.

[0054] As used herein, a “second metal component” may be the same as, or different from, the metalcomponent bonded thereto.

[0055] In the dry process of the present method, the UV-C functionalized catalyst slurry is dried to form a catalyst paste which is then dispersed onto a surface of the carbon component when the spent material related to direct electric power generation and storage is provided in unshredded form or mixed with the spent material related to direct electric power generation and storage when the spent material is in shredded form.

[0056] In the wet process of the present method, the spent material related to direct electric power generation and storage, in shredded or un-shredded form, is immersed in the UV-C functionalized catalyst slurry.

[0057] Both processes enable re-use of the materials employed, i.e. the catalyst and the aqueous acidic medium or de-ionized water.

[0058] Figure 1 illustrates a dry process of a method for processing spent material related to direct electric power generation and storage described herein;

[0059] Figure 2 illustrates a system for performing the dry process of the method for processing spent material related to direct electric power generation and storage described herein; Figure 3 illustrates a wet process of a method for processing spent material related to direct electric power generation and storage described herein;

[0060] Figure 4 illustrates a system for performing the wet process of the method for processing spent material related to direct electric power generation and storage described herein; Figure 5 illustrates a bench scale experimental setup for performing the wet process of the method for processing spent material related to direct electric power generation and storage described herein;

[0061] Figure 6 illustrates separated spent material components related to direct electric power generation and storage obtained in the bench scale experiment; and,

[0062] Figures 7 to 26 illustrate measured results of the bench scale experiment.

[0063] The method for processing spent material related to direct electric power generation and storage comprising a metal component bonded to a carbon component and / or a second metal component employs a step change approach of shifting within the carbon component and / or second metal component to enable increased percolation and dissociation of the metalcomponent by using photo-reductive catalytic techniques at room temperature in a dry or wet process. Functionalized high band gap materials such as, for example, functionalized boron nitride nanosheets, hydroxylated gallium nitride, and hydroxylated silicon carbide, with high thermal conductivity are modified to improve domain shifting from the charged carbon. With a low pH aqueous acidic medium or de-ionized water, this leads to a successful localization of the functionalized nanomaterials at the metal-carbon interface and causes a displacement of critical transition metal oxides due to UV-C functionalization, which can be performed at any wavelength within the UV-C range between 100 nm and 280 nm. In a circulating liquid, this approach enhances then surface renewal of the metal component constantly with ease of transition metal liberation and separation of the metal component from the carbon component and / or second metal component. In the dry process, the catalyst material selected is first subjected to UV-C, for example, at 184 nm at 3W, as a concentrated paste (typically 40% catalyst with deionized water or higher) for a period of 1 hour. The concentrated paste was applied to the coated surface of the electrode and exposed to UV-C for intervals of 20 minutes to 1 hour and separation between the current collected and the electrode active materials (in the carbon bound domain) was achieved.

[0064] Chemical functionalization may be applied to improve interfacial interactions. For example, chemically active functional groups were applied on pristine hexagonal boron nitride (hBN) edges Gallium nitride wafer (GNW) functionalization was achieved using hydrofluoric (HF) acid or alcohol (in particular, ethanol) treatment for cleaning and / or sonication.

[0065] Catalyst modification may be performed to increase the thermal conductivity in the charged carbon domain by percolating the carbon component where the heat transfer and UV-C functionalization is efficient while the interfacial thermal resistance is minimized. This selective co-localization approach controls the distribution of the functionalized nanomaterials and separates the carbon component and / or second metal component from the metal component.

[0066] The method for processing spent material related to direct electric power generation and storage comprising a metal component bonded to a carbon component and / or a second metal component may be executed as a dry process, illustrated in Figures 1 and 2, or as a wet process, illustrated in Figures 3 and 4. The spent material related to direct electric power generation and storage may be lithium-ion battery, photovoltaics, fuel cell waste material, ora combination thereof, which may be provided in ground or shredded form, un-shredded form, or a combination thereof. Common to both processes are steps related to the initial functionalization of the catalyst. To this end, the catalyst, a high band gap nanomaterial, is suspended in an aqueous acidic medium or de-ionized water to form a catalyst slurry. For example, boron nitride, gallium nitride, or silicon carbide nanomaterial may be employed as the catalyst. The aqueous acidic medium may be made of a mineral acid or an organic acid having a pH between 2 and 3 such as, for example, a IM or 2M nitric acid (HNO3) solution.

[0067] For the initial UV-C functionalization the catalyst slurry 14 is disposed in an enclosure 10 such as, for example, a chemical reactor vessel, having at least an UV-C radiation source 16 disposed therein. Using the UV-C radiation source 16 disposed, for example, near the top of the enclosure 10, the catalyst slurry 14, disposed in a bottom portion of the enclosure 10, is then initially functionalized by UV-C irradiating the catalyst slurry 14 for a predetermined time interval, for example, 30 minutes to one hour. To increase efficiency, the enclosure 10 may comprise an inside surface that is capable of reflecting the UV-C radiation onto at least a portion of the catalyst slurry 14.

[0068] Optionally, the catalyst slurry 14 may be sonicated prior to the initial UV-C functionalization for point defect generation in the catalyst. For example, the sonication may be performed in the same enclosure 10 as the UV-C functionalization with the enclosure 10 having at least an ultrasound emitter 12 disposed therein. Alternatively, the sonication may be performed in another enclosure than the enclosure 10 at the cost of having to transfer the catalyst slurry 14 after the sonication into the enclosure 10 for the UV-C functionalization. Using the ultrasound emitter 12 disposed, for example, near the top of the enclosure 10, the catalyst slurry 14, disposed in a bottom portion of the enclosure 10, is then sonicated by exposing the catalyst slurry 14 to ultrasound radiation, for example, in the mid-frequency ultrasound range of 200kHz to 800 kHz, for a predetermined time interval. Sonication of the catalyst slurry varies from a period of 20 minutes to 1 hour in a coolant jacketed reactor. Typical period for sonication was 30 minutes. Sonicating the catalyst slurry 14 may accelerate the separation process but may require higher acid concentrations.

[0069] After the initial UV-C functionalization, the method bifurcates into one of the dry process and the wet process. In the dry process, the UV-C functionalized catalyst slurry 14 is removed from the enclosure 10 for drying to form an UV-C functionalized catalyst paste14A. The UV-C functionalized catalyst slurry 14 may be dried using a drying assembly 18 comprising centrifuge 18A, filter 18B, and oven 18C for centrifuging, filtering, and oven drying (for example, at 80°C for 16 hours) the same.

[0070] The UV-C functionalized catalyst paste 14A is then dispersed on a surface of the carbon component 20A of the spent material related to direct electric power generation and storage 20 when the spent material is in un-shredded form and placed onto the bottom of enclosure 11 such as, for example, a chemical reactor vessel, having at least an UV-C radiation source 17 disposed therein. Using the UV-C radiation source 17 disposed, for example, near the top of the enclosure 11, the UV-C functionalized catalyst paste 14 A, disposed onto the surface of the carbon component 20 A, is then further functionalized by UV-C irradiating the same during the time interval needed until the carbon component 20A is separated from the metal component 20B of the spent material related to direct electric power generation and storage 20, which may take several hours (up to 24 hours). The termination of the separation step may be determined based on visual inspection of the spent material related to direct electric power generation and storage 20 if separation has occurred or after a predetermined time interval which has been, for example, determined in an empirical manner. To increase efficiency, the enclosure 11 may comprise an inside surface that is capable of reflecting the UV-C radiation onto at least a portion of the catalyst paste 14A. Alternatively, the enclosure 10 may be employed for the separation step. In case the spent material related to direct electric power generation and storage is shredded (for example, black mass), the catalyst paste 14A is mixed with the shredded waste material. Optionally, the UV-C radiation source 17 may not be employed or turned off after a predetermined time interval since the catalyst stays UV-C functionalized for some time, which can be determined in an empirical manner.

[0071] After the separation, the spent material components 20A, 20B are washed in water to remove the catalyst from the separated spent material components 20 A, 20B. In case the spent material related to direct electric power generation and storage is shredded, a sieve may be employed for straining the separated spent material components from the water. The separated spent material components 20A, 20B are then dried and may be provided for further processing to manufacture new electronic components, while the catalyst may be reused by providing the water with the catalyst suspended therein to the drying assembly 18 for generating the catalyst paste 14A. Since the catalyst stays UV-C functionalized for some time, which can be determined in an empirical manner, the initial functionalization and theUV-C irradiation during the separation may be omitted.

[0072] Alternatively, if it is expected that the catalyst will not be re-used for some time in which case the catalyst may become inactive, the separated spent material components 20A, 20B may be washed in the aqueous acidic medium or de-ionized water forming a catalyst slurry which may then be disposed in the enclosure 10 for UV-C functionalization and, optionally, sonication.

[0073] In the wet process, the spent material related to direct electric power generation and storage 20 is immersed in the UV-C functionalized catalyst slurry 14 disposed in the bottom portion of the enclosure 10. The spent material related to direct electric power generation and storage 20 may be immersed in shredded form or un-shredded form. Using the UV-C radiation source 16, the catalyst slurry 14 is then further functionalized by UV-C irradiating the same during the time interval needed until the carbon component 20A is separated from the metal component 20B of the spent material related to direct electric power generation and storage 20, which may take several hours (up to four hours). The termination of the separation step may be determined based on visual inspection of the spent material related to direct electric power generation and storage 20 if separation has occurred or after a predetermined time interval which has been, for example, determined in an empirical manner.

[0074] Alternatively, another enclosure than the enclosure 10 may be employed for the separation at the cost of having to transfer the catalyst slurry 14 from the enclosure 10 after the UV-C functionalization. Further alternatively, the separation may be implemented as a continuous process, for example by placing the spent material related to direct electric power generation and storage onto a conveyor and passing the same under one or more rollers with the rollers receiving the catalyst slurry 14 and dispersing the same onto the spent material related to direct electric power generation and storage.

[0075] Optionally, the UV-C radiation source 16 may not be employed or turned off after a predetermined time interval since the catalyst stays UV-C functionalized for some time, which can be determined in an empirical manner.

[0076] After the separation, the spent material components 20A, 20B are removed from the catalyst slurry 14. In case the spent material components are shredded, a sieve may be employed forstraining the spent material components from the catalyst slurry 14. The separated spent material components 20 A, 20B are then dried and may be provided for further processing to manufacture new electronic components, while the catalyst slurry 14 may be re-used for another separation process.

[0077] Since the catalyst stays UV-C functionalized for some time, which can be determined in an empirical manner, the initial functionalization and the UV-C irradiation during the separation may be omitted. Alternatively, if the catalyst slurry 14 has become inactive, the catalyst slurry 14 can again be UV-C functionalized and, optionally, sonicated.

[0078] Both processes may be performed at room temperature (commonly understood as a temperature range between 15°C and 25°C), except for the oven drying in the dry process.

[0079] The method for processing spent material related to direct electric power generation and storage comprising a metal component bonded to a carbon component and / or a second metal component has been implemented using a bench scale experimental setup with a 184 nm 3 W UV-C light source at room temperature.

[0080] Figure 5 illustrates a bench scale experimental setup with a 184 nm 3 W UV-C light source 16 disposed in a laboratory glass reactor vessel 10 with a calendared cathode scrap section 20 immersed in catalyst slurry 14. It is noted that aluminum foil disposed onto the outside surface of the vessel 10 for blocking visible light and reflecting the UV-C light has been removed to enable a view into the vessel 10.

[0081] Figure 6 illustrates the aluminum current collector 20B, which was separated from the carbon component 20A in 45 minutes.

[0082] Figure 7 illustrates Fourier Transform Infrared Spectroscopy (FTIR) analysis of aluminium cathode scrap in the carbon bound domain for bond stretching with reference to (AI Vrgn) as the current collector (Al) before treatment and positions (1), (2) (3) and centre of delaminated section (Al DeLam Positionl, Al_DeLam_Position2, Al_DeLam_Position3 and

[0083] Al DeLam Centre) after separation from cathode material on both sides of the Al current collector. This indicates that the aluminum current collector will show some binder (PVDF) with molecular fragments of broken vinylidene fluoride chains after carbon bound domain(critical metals) removal. In the case of Al Delam Centre, it is shown that the current collector can be obtained with the quality of Al_Vrgn for direct re-use. Variations in 1=1400-1000 cm-1 are due to delineation of carbon-metal matrix with stretching of binder without breakdown.

[0084] Figure 8 confirms the breakdown of binder (PVDF) in black mass. As shown, mechanical shear applied during black mass production does not break down the PVDF (higher diameter size distribution of PVDF). However, when the black mass is subjected to photocatalytic reduction using UV-C, the size distribution is significantly reduced as the binder breaks down and the metals-carbon agglomerates (bound by PVDF) found in the carbon bound domain are available for recovery from the black mass.

[0085] Figure 9 shows in a micrograph the benefit of UV-C treatment wherein the transition metals are concentrated (saturation critical metals) while the charged carbon and binder are in separate domains. This allows rapid recovery of critical metals from black mass.

[0086] Figure 10 shows in a micrograph the breakdown of the binder with smearing or stretching of PVDF after UV-C treatment in the presence of catalyst.

[0087] Figure 11 illustrates X-Ray Diffraction (XRD) binder peaks (2 <15 degrees) for cathode black mass before catalytic UV-C treatment (Cathode BM) and after catalytic UV-C treatment (Delam_Cat) in the presence of GaN catalyst, showing binder destruction and also a shift in metal oxides peaks.

[0088] Further investigations analyzed the delamination period for breakdown kinetics of black mass (BM1) employing the method for processing spent material related to direct electric power generation and storage comprising a metal component bonded to a carbon component and / or a second metal component, which has been implemented using the bench scale experimental setup illustrated in Figure 5 with a 184 nm 3 W UV-C light source at room temperature. For the experiments, 1 gram of black mass, and 25 mL DI water were used.

[0089] Figures 12 and 13 illustrate a Scanning Electron Microscopy (SEM) image of the black mass before processing (back scatter mode with Energy Dispersive Xray (EDX) analysis at several spectral points) and an EDX analysis at spectral point 3 (spectrum 3), respectively. It is notedthat the EDX analysis has not found any fluorine (F) atoms as F is not released from the binder.

[0090] Employment of a SiC catalyst in the presence of UV-C causes breakdown of the binder and release of F atoms. Figures 14 to 16 illustrate a Scanning Electron Microscopy (SEM) image of the black mass after two hours of processing time (back scatter mode with Energy Dispersive Xray (EDX) analysis at several spectral points) and EDX analyses at spectral points 34 and 35 (spectra 34 and 35), respectively. The EDX analyses indicate the presence of F atoms.

[0091] Similarly, employment of a GaN catalyst in the presence of UV-C also causes breakdown of the binder and release of F atoms. Figures 17 and 18 illustrate a Scanning Electron Microscopy (SEM) image of the black mass after two hours of processing time (back scatter mode with Energy Dispersive Xray (EDX) analysis at several spectral points) and an EDX analysis at spectral point 50 (spectrum 50), respectively. The EDX analysis indicates the presence of F atoms.

[0092] Figures 19 and 20 illustrate volume distribution and cum. vol. distribution, respectively, of dry black mass (BM1) vs particle diameter over time (breakdown kinetics) using GaN and UV-C exposure. Particle breakdown and binder release results in larger agglomerates over longer periods of time.

[0093] Figures 21 and 22 illustrate volume distribution and cum. vol. distribution, respectively, of dry black mass (BM1) vs particle diameter over time (breakdown kinetics) using SiC and UV-C exposure. Particle breakdown and binder release results in larger agglomerates over longer periods of time.

[0094] Figures 23 to 26 illustrate comparative particle size distributions for unprocessed black mass, black mass processed with both catalysts (GaN & SiC), black mass processed with GaN, and black mass processed with SiC, respectively. Figures 24 to 26 show the benefits of combining the catalysts GaN & SiC. (left vertical axis - Vol. Distribution %, right vertical axis -Cumulative vol. distribution %, and abscissa - particle diameter, |im)

[0095] The above disclosure and figures are intended to be illustrative and not exhaustive. Thedescription will suggest many variations and alternatives to one of ordinary skill in the art. Those familiar with the art may recognize other equivalents to the specific embodiments described herein within, without departing from the scope thereof.

Claims

What is claimed is:

1. A method for processing spent material related to direct electric power generation and storage comprising:providing the spent material related to direct electric power generation and storage, the spent material related to direct electric power generation and storage comprising a metal component bonded to a carbon component and / or a second metal component;providing a catalyst;UV-C functionalizing the catalyst; and,using the UV-C functionalized catalyst for separating the metal component from the carbon component and / or the second metal component by breaking down a binder bonding the metal component to the carbon component and / or the second metal component.

2. The method of claim 1, further comprising suspending the provided catalyst in an aqueous acidic medium or de-ionized water to form a catalyst slurry and UV-C functionalizing the catalyst slurry.

3. The method of claim 2, wherein UV-C radiation is provided to the catalyst slurry while separating the metal component from the carbon component and / or the second metal component.

4. The method of claim 3, wherein the UV-C functionalization and the separation are performed in at least an enclosure having the catalyst and at least a UV-C radiation source disposed therein and wherein the at least an enclosure is adapted for blocking visible radiation.

5. The method of claim 4, wherein the enclosure comprises an inside surface that is capable of reflecting the UV-C radiation and wherein at least a portion of the UV-C radiation is reflected onto at least a portion of the catalyst.

6. The method of claim 2, further comprising sonicating the catalyst prior to UV-C functionalizing.

7. The method of claim 6, wherein the catalyst is sonicated with ultrasound radiation in afrequency range of 200kHz to 800 kHz.

8. The method of claim 2, wherein the catalyst is a high band gap nanomaterial.

9. The method of claim 8, wherein the catalyst is one of a boron nitride, gallium nitride, or silicon carbide nanomaterial.

10. The method of claim 2, wherein the UV-C functionalization and the separation are performed at room temperature.

11. The method of claim 2, wherein the aqueous acidic medium comprises a mineral acid or an organic acid.

12. The method of claim 11, wherein the aqueous acidic medium comprises nitric acid.

13. The method of claim 1, wherein the spent material related to direct electric power generation and storage is provided in ground or shredded form, un-shredded form, or a combination thereof.

14. The method of claim 13, wherein the spent material related to direct electric power generation and storage is a lithium-ion battery, photovoltaics, fuel cell waste material, or a combination thereof.

15. The method of claim 1, further comprising re-using the catalyst for another separation process.

16. The method of claim 15, wherein the catalyst is still functionalized and wherein during re-use the other separation process is performed absent provision of UV-C radiation.

17. The method of claim 2, further comprising:drying the UV-C functionalized catalyst slurry to form a UV-C functionalized catalyst paste; and,dispersing the UV-C functionalized catalyst paste on a surface of the carbon component and / or the second metal component of the spent material related to direct electricpower generation and storage when the waste material is in un-shredded form or mixing the catalyst paste with the spent material related to direct electric power generation and storage when the spent material is in shredded form.

18. The method of claim 17, wherein the drying of the UV-C functionalized catalyst slurry comprises centrifuging and filtering.

19. The method of claim 17, further comprising:washing the separated spent material components in water for removing the catalyst from the separated spent material components; and,re-using the catalyst.

20. The method of claim 19, further comprising drying the water with the catalyst to form a catalyst paste.

21. The method of claim 2, further comprising immersing the spent material related to direct electric power generation and storage in the catalyst slurry.

22. The method of claim 21, further comprising:removing the catalyst slurry from the separated spent material components; and, re-using the catalyst slurry.

23. The method of any one of claims 1 to 22, wherein the second metal component is the same as, or different from, the metal component bonded thereto.

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