Lithium-Ion Battery Comminution in Water to Limit Heat and HF
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Solution Overview
Problem
Existing methods for recycling lithium-ion batteries are inefficient, leading to the loss of valuable raw materials and pose safety risks due to incomplete discharge and thermal recycling, which can result in fires and explosions.
Innovation Solution
A method involving mechanical comminution of lithium-ion batteries in the presence of an aqueous medium with controlled temperature and water supply to prevent overheating and hydrogen fluoride release, followed by multi-stage separation and wet chemical processing to recover valuable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are completely discharged before processing, then safety risks are reduced, but processing time increases significantly
Solution Approach 1:
The patent applies preliminary action by discharging batteries to a residual charge of 30% or less before comminution, which is sufficient to reduce safety risks (short-circuiting, thermal runaway) while avoiding the time-consuming complete discharge. This preliminary discharge level maintains safety during mechanical processing without requiring full depletion of battery charge.
Solution Approach 2:
The patent changes the discharge parameter from complete discharge (0% residual charge) to partial discharge (30% or less residual charge). This parameter modification achieves the essential safety benefit of reducing voltage to prevent short-circuiting and thermal runaway, while significantly reducing the time required compared to complete discharge.
2Ease of manufacture
If thermal recycling is used to process batteries, then material separation is achieved, but valuable raw materials are lost
Solution Approach 1:
The patent replaces thermal recycling (thermal system) with mechanical comminution followed by wet chemical processing. Instead of using high-temperature thermal processes that cause material loss, the invention uses mechanical size reduction combined with aqueous-based separation methods, thereby achieving material separation while preserving valuable raw materials like lithium, graphite, nickel, cobalt, and other metals.
Solution Approach 2:
The patent employs hydraulic principles through wet chemical processing and aqueous medium-based separation methods. Water and other liquids are used to facilitate material separation and recovery, replacing thermal processes and enabling efficient recovery of valuable materials without the material loss associated with high-temperature thermal recycling.
3Productivity
If battery cells are shredded and directly processed through wet chemical process, then processing efficiency improves, but material load on wet chemical process doubles
Solution Approach 1:
The patent applies segmentation by dividing the processing into distinct stages: first mechanical comminution to reduce size, then separation of lightweight materials (plastics, aluminum foil) from heavy materials (black mass containing valuable metals), and finally wet chemical processing only on the concentrated black mass fraction. This segmentation reduces the material load on wet chemical processing by pre-concentrating the target materials.
Solution Approach 2:
The patent extracts and removes lightweight materials (plastics, aluminum foil, copper) from the battery components before subjecting the remaining material to wet chemical processing. This extraction step concentrates the valuable materials (lithium, nickel, cobalt, manganese) into a smaller volume of black mass, thereby reducing the overall material load on the wet chemical process while maintaining processing efficiency.
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 method effectively recovers over 95% of battery components for recycling, minimizing material loss and safety risks while reducing energy consumption and environmental impact.
Implementation Method 1
water is supplied in such a quantity and at such a temperature that the mixture does not heat up to a temperature of more than 40 °C
Implementation Method 2
the hydrolysis reaction of LiPF6 in pure water, unlike the hydrolysis in contaminated electrolyte water, proceeds very slowly
Data Source
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AI summary
The invention relates to a method for preparing and evaluating lithium-ion batteries, having at least one step in which the batteries (2, 10) or comminuted in the presence of an aqueous medium (12), wherein the batteries (2, 10) are comminuted with a remaining charge of maximally 30% in a comminuting device (73) while adding water (12), and the water (12) is supplied in such a quantity and at such a temperature that the mixture is not heated above a temperature of more than 40 °C, preferably above 30 °C, during the comminuting process. The invention also relates to a corresponding facility (71).