High-Nickel Cathode Precursor Synthesis via Acid Leaching
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Solution Overview
Problem
The existing manufacturing process for high-nickel positive electrode active materials is time-consuming and costly due to the need for multiple smelting and liquefaction steps, particularly when preparing materials with high nickel content, which limits their application in energy storage devices like electric vehicles.
Innovation Solution
A method involving leaching metal components from raw materials containing nickel and cobalt using acid, followed by co-precipitation with chelating agents and hydroxide precipitants to directly produce a precursor for the positive electrode active material, skipping the reduction and separation steps, and incorporating additional nickel, cobalt, or manganese sulfates to achieve a high-nickel content of 60% or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional smelting and liquefaction processes are used to prepare high-nickel positive electrode active material, then high nickel content (60 at % or more) can be achieved, but manufacturing time and cost are excessively increased
Solution Approach 1:
The patent extracts the essential metal components (nickel, cobalt, manganese) from raw materials through acid leaching, separating them from the ore matrix. This extraction approach eliminates the need for traditional smelting and liquefaction processes, directly obtaining metal salts suitable for precursor synthesis, thereby significantly reducing manufacturing time while maintaining high nickel content
Solution Approach 2:
The patent performs preliminary acid leaching of metal components from raw materials before precursor synthesis. By pre-extracting and purifying the metal salts in advance, the process eliminates subsequent smelting and liquefaction steps, achieving time reduction while ensuring the required nickel content in the final product
2Quantity of substance
If conventional smelting and liquefaction processes are used to prepare high-nickel positive electrode active material, then high nickel content (60 at % or more) can be achieved, but manufacturing cost is excessively increased
Solution Approach 1:
The patent extracts metal components through acid leaching, replacing the complex and costly smelting and liquefaction processes. This extraction method using common acids and standard chemical operations significantly reduces equipment investment and operational costs while achieving the required high nickel content
Solution Approach 2:
The patent changes the chemical parameters of the process by using acid leaching instead of high-temperature smelting. This parameter change from thermal processing to chemical processing eliminates the need for expensive smelting furnaces and reduces energy consumption, thereby lowering manufacturing cost while maintaining product quality
3Quantity of substance
If nickel metal is obtained from nickel oxide ore or sulfide ore and converted into nickel sulfate again, then high nickel content can be achieved, but time and cost are significantly increased
Solution Approach 1:
The patent merges the metal extraction and precursor preparation steps into a single integrated acid leaching process. By combining these operations, the patent eliminates the separate smelting, liquefaction, and nickel sulfate preparation steps, significantly improving manufacturing efficiency while achieving high nickel content in the final product
Solution Approach 2:
The patent performs preliminary acid leaching to directly obtain purified metal salts containing nickel, cobalt, and manganese in the required ratios. This preliminary action eliminates the need for subsequent conversion to nickel sulfate and other intermediate processing steps, thereby improving productivity while ensuring high nickel content
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the smelting and liquefaction process, reducing time and cost while maintaining high nickel content, thereby improving the efficiency and cost-effectiveness of producing high-nickel positive electrode active materials with enhanced thermal stability and capacity characteristics.
Implementation Method 1
separating a liquid intermediate by leaching a metal component in the raw material using an acid
Implementation Method 2
co-precipitating a precursor of a positive electrode active material by adding a chelating agent and a hydroxide precipitant to the liquid intermediate
Data Source
AI summary
The present invention provides a method for manufacturing a high-nickel positive electrode active material comprising the steps of preparing a raw material containing nickel and cobalt; separating a liquid intermediate by leaching a metal component in the pulverized raw material using an acid and removing impurities; and co-precipitating a precursor of a positive electrode active material by adding a chelating agent and a hydroxide precipitant to the liquid intermediate.