Lithium Battery Cathode Recycling with Selective Metal Separation
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Solution Overview
Problem
Existing lithium battery recycling technologies are inefficient, costly, and environmentally harmful due to the presence of toxic substances and valuable metals, leading to soil and water contamination.
Innovation Solution
An apparatus and method for recycling lithium battery cathode materials using a pretreatment device, acid leaching, and extraction processes, including a heating furnace, magnetic separation, and chemical extraction with agents like diisooctyl phosphate, to separate and recover valuable metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing recycling technologies are used, then lithium batteries can be processed, but the treatment process is complicated and recycling efficiency is low
Solution Approach 1:
The recycling process is divided into distinct functional modules: pretreatment device for initial processing, acid leaching device for metal extraction, filtration device for separation, and heating furnace for solid product treatment. Each module performs a specific function, allowing independent optimization and simplifying the overall complex process while improving efficiency.
Solution Approach 2:
The apparatus is designed to handle multiple types of lithium battery cathode materials (lithium iron phosphate and ternary materials) through a unified process flow. The system can process different battery types without requiring complete process redesign, improving recycling efficiency across various battery chemistries while maintaining a standardized treatment approach.
2Productivity
If existing recycling technologies are used, then lithium batteries can be processed, but recycling costs are high
Solution Approach 1:
The system efficiently recovers valuable metals (lithium, nickel, cobalt, manganese, copper, iron, aluminum) from discarded batteries through acid leaching and selective extraction. By maximizing metal recovery rates and producing high-purity products suitable for direct reuse in new batteries, the process reduces recycling costs while improving efficiency.
Solution Approach 2:
The apparatus converts harmful toxic substances (heavy metals, electrolytes, phenyl compounds, ester compounds) into recoverable resources. The acid leaching process transforms toxic heavy metals into extractable metal ions, while the heating furnace converts organic pollutants into manageable gaseous products, turning environmental hazards into economic benefits.
3Adaptability or versatility
If acid leaching is performed on mixed battery types, then both lithium iron phosphate and ternary batteries can be processed, but separation of different metals becomes more difficult
Solution Approach 1:
The system uses diisooctyl phosphate as an intermediary extraction agent that selectively binds to specific metal ions in the leachate. This intermediary substance facilitates the separation of different metals (nickel, cobalt, manganese, lithium, iron, phosphorus) from the mixed leachate solution, enabling efficient metal recovery even from mixed battery types without increasing overall process complexity.
4Object-affected harmful factors
If heavy metals are not properly treated, then processing is simpler, but soil and groundwater contamination occurs
Solution Approach 1:
The apparatus transforms harmful heavy metals into recoverable resources through acid leaching and selective extraction. Instead of simply disposing of toxic heavy metals, the system converts them into pure metal products that can be reused, eliminating environmental contamination while maintaining a manageable treatment process through standardized modular equipment.
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
The process efficiently recycles metals from lithium batteries, reducing environmental impact and enabling direct reuse in new batteries, while minimizing waste and pollution.
Implementation Method 1
a device of acid leaching, configured to obtain leachate
Implementation Method 2
a heating furnace for heating the solid products, obtained after acid leaching and solid-liquid filtration, in an oxygen-containing atmosphere
Implementation Method 3
heating the solid products, obtained after acid leaching and solid-liquid filtration, in an oxygen-containing atmosphere
Implementation Method 4
a first extraction device for performing extraction on the leachate, wherein diisooctyl phosphate is extraction agent
Implementation Method 5
the device for pretreating includes a crusher, a device of magnetic separation
Implementation Method 6
the device for pretreating includes a pyrolysis furnace
Data Source
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AI summary
The present invention provides an apparatus for separating and recycling metal elements in cathode materials of lithium batteries, comprising a device for pretreating lithium batteries, configured to obtain a mixture of powders containing positive-electrode materials; a device of acid leaching, configured to obtain leachate; if the to-be-recycled lithium battery contain a lithium iron phosphate battery, the apparatus further comprises a heating furnace for heating the solid products, obtained after acid leaching and solid-liquid filtration, in an oxygen-containing atmosphere; if the to-be-recycled lithium battery contains a ternary lithium battery, the apparatus further comprises a first extraction device for performing extraction on the leachate, wherein diisooctyl phosphate is extraction agent.