Li-Ion Battery Graphite Recovery by Wet Comminution Separation
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Solution Overview
Problem
Existing methods for recycling lithium-ion batteries are inefficient, lead to the loss of valuable materials like lithium, graphite, nickel, and cobalt, and pose safety risks due to incomplete discharge and thermal recycling, which can result in fires and inefficient separation of battery components.
Innovation Solution
A method involving controlled comminution of batteries with water to separate graphite-enriched and graphite-depleted fractions, followed by mechanical and fluid processing to recover valuable metals and graphite, minimizing deflagration risks and reducing the need for complete discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are completely discharged before recycling, then safety risks are reduced, but the process becomes extremely time-consuming and energy-intensive
Solution Approach 1:
The patent applies preliminary action by performing comminution and separation processes before complete discharge is achieved. The battery is mechanically broken down and components are separated while still partially charged, avoiding the time-consuming complete discharge step while maintaining safety through controlled mechanical processing and immediate component separation.
Solution Approach 2:
The patent replaces the electrical discharge process with a mechanical comminution process. Instead of using electrical current to deplete the battery, mechanical forces are applied to break down the battery structure and separate components, achieving both size reduction and component isolation without requiring complete electrical discharge.
2Use of energy by moving object
If thermal recycling methods are used to recover metals, then energy input is reduced, but valuable materials like lithium, graphite, nickel, and cobalt are completely or extensively lost
Solution Approach 1:
The patent applies segmentation by mechanically breaking down the battery into distinct components through comminution and separation processes. This physical segmentation allows for the recovery and preservation of valuable materials like lithium, graphite, nickel, and cobalt in their respective component forms, preventing the material loss that occurs in thermal recycling where everything is melted down together.
Solution Approach 2:
The patent extracts valuable materials from the battery through mechanical separation processes. The comminution and classification steps selectively separate and extract components containing valuable materials (cathode, anode, electrolyte) from the battery structure, preserving these materials for recovery rather than losing them in thermal processing.
3Productivity
If battery cells are comminuted without sufficient separation, then processing efficiency increases, but the amount of material requiring wet-chemical processing doubles, increasing complexity
Solution Approach 1:
The patent applies preliminary action by performing comminution and mechanical separation before wet-chemical processing. This preliminary mechanical breakdown and classification of battery components reduces the complexity and volume of material that subsequently requires wet-chemical treatment, rather than comminuting everything without prior separation.
Solution Approach 2:
The patent uses mechanical comminution and separation processes to pre-process battery materials before chemical treatment. This mechanical pre-processing step replaces the need for more complex chemical processing by physically separating components that would otherwise require extensive chemical treatment, thereby reducing overall process complexity.
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 method effectively recovers over 95% of valuable raw materials with reduced energy consumption and safety risks, enabling efficient recycling of lithium-ion batteries by minimizing hydrogen fluoride release and optimizing the separation process.
Implementation Method 1
the ambient fluid is an aqueous solution containing calcium or magnesium, which are present as basic hydroxides Ca(OH)2 or Mg(OH)2 and react in aqueous solution with the hydrogen fluoride (HF for short) produced during the decomposition of LiPF6 to form poorly soluble CaF2 or MgF2 and are bonded in this way
Implementation Method 2
the batteries with a residual charge of no more than 30% are comminuted with the addition of water in a comminuting device so that a mixture of comminuted batteries and water is obtained
Data Source
AI summary
The present invention relates to a process for obtaining graphite, and optionally metals of value, which are preferably selected from at least one of the metals of the first and/or the third main group and/or at least one of the metals from the 7th to 11th secondary group, from lithium-ion batteries. The invention also relates to a corresponding system (71).