Battery Compression for Electrolyte Removal in Metal Melting
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Solution Overview
Problem
Existing methods for recovering used batteries in metal melting furnaces are energy-intensive due to water evaporation from electrolytes and prone to refractory corrosion from potassium and chlorides, leading to increased operational costs and maintenance issues.
Innovation Solution
The method involves compressing batteries to remove electrolytes before introduction into the furnace, forming composite briquettes with metal turnings and additives to prevent corrosion, allowing for efficient recovery of valuable elements while minimizing water evaporation and refractory damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batteries and accumulators are introduced directly into the metal melting furnace, then the recovery process is simple, but water evaporation is energy-intensive and refractory corrosion is accelerated
Solution Approach 1:
The patent applies preliminary action by removing the electrolyte from batteries and accumulators before introducing them into the melting furnace. This pre-treatment step eliminates the harmful electrolyte components (water, potassium hydroxide, chlorides) that would otherwise require energy-intensive evaporation and cause refractory corrosion, while still allowing the valuable metals to be recovered in the furnace.
2Ease of manufacture
If batteries and accumulators are introduced directly into the metal melting furnace, then the process requires minimal preparation, but potassium hydroxide and chlorides cause accelerated corrosion of refractories and exchangers
Solution Approach 1:
The patent applies the extraction principle by removing the harmful electrolyte (containing potassium hydroxide and chlorides) from the batteries and accumulators before they enter the melting furnace. This separation eliminates the source of corrosion, protecting the refractories and heat exchangers while allowing the valuable metal components to be processed.
3Use of energy by moving object
If electrolyte is removed by compression before furnace introduction, then energy consumption is reduced and refractory corrosion is minimized, but additional processing steps are required
Solution Approach 1:
The patent applies self-service by using the compression step to simultaneously achieve multiple objectives: removing the electrolyte, compacting the battery materials into a manageable form, and preparing the charge for efficient furnace loading. This multi-functional approach reduces the need for separate processing steps despite the added complexity of the compression 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
This approach reduces energy consumption, minimizes refractory corrosion, and enables the recovery of valuable metals like manganese, nickel, and rare earths, while ensuring environmental compliance and real-time pollution control.
Implementation Method 1
the batteries and/or accumulators are subjected to a compression operation to remove the electrolytes contained in the batteries and/or accumulators
Implementation Method 2
introduction of the batteries and/or accumulators in the metal melting furnace such as the cupola
Data Source
Figure 1
AI summary
The invention relates to a method for recycling used batteries, such as saline, alkaline, button cell, and accumulator batteries, by introducing the batteries and/or accumulators as a charge into a metal melting furnace at the furnace's opening. The invention is characterized in that the batteries and/or accumulators are subjected to a compression operation to remove the electrolytes they contain, prior to being introduced into the metal melting furnace. The invention is applicable to the recycling of used batteries and accumulators.