Battery Plastic Recovery Using Two-Stage Comminution Separation
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Solution Overview
Problem
Current battery recycling methods face challenges in efficiently separating and recovering plastic materials from lithium-ion batteries, as they often become contaminated with metals and other components, leading to reduced recyclability and efficiency.
Innovation Solution
A system and method involving a two-stage size reduction process, where the primary size reduction occurs under immersion conditions to liberate metals and black mass, followed by a non-immersion secondary size reduction to break down plastics further, accompanied by mechanical washing and separation to isolate plastics from metals and black mass, utilizing a plastic separator tank with a movable agitator to enhance precipitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-stage size reduction process is used to process battery materials, then the processing speed is high and the structure is simple, but the plastic materials remain contaminated with metals and black mass, reducing recyclability
Solution Approach 1:
The patent divides the size reduction process into two distinct stages: a first size reduction process that processes whole batteries to liberate materials, and a second size reduction process that further reduces the liberated materials. This segmentation allows each stage to be optimized for its specific function, with the first stage focusing on liberation and the second stage focusing on fine size reduction and separation, thereby resolving the contradiction between processing speed and separation precision.
2Loss of time
If plastic materials are processed without further size reduction after liberation, then the processing time is short, but the plastic contamination with metals and black mass reduces the recyclability
Solution Approach 1:
The patent implements a segmented approach where the first size reduction process liberates materials quickly, and the second size reduction process is specifically applied to the liberated materials to achieve fine separation. This allows the majority of processing to be completed in the first stage, minimizing total processing time while ensuring high separation precision in the second stage for the critical plastic material recovery.
Solution Approach 2:
The first size reduction process performs a preliminary liberation of materials from the battery structure before the second size reduction process is applied. This preliminary action separates the plastics from the bulk of the metal and black mass, so that the subsequent second size reduction process only needs to handle the liberated materials, reducing the overall processing time while achieving high separation precision.
3Manufacturing precision
If a two-stage size reduction process with non-immersion secondary reduction is used, then the plastic separation precision is improved, but the device complexity increases
Solution Approach 1:
The patent segments the processing system into two distinct units: a first size reduction apparatus that operates under immersion conditions for liberation, and a second size reduction apparatus that operates without immersion for fine size reduction. This segmentation allows each apparatus to be relatively simple in design, optimized for its specific function, rather than requiring one complex apparatus to perform all functions.
Solution Approach 2:
The patent introduces an intermediary step where the liberated materials from the first size reduction process are transferred to the second size reduction process. This intermediary transfer allows the two processes to be independent and relatively simple, with each handling a specific stage of the overall separation, rather than requiring a single complex integrated system.
4Use of energy by moving object
If plastic materials are recovered with minimal processing, then the energy consumption is low, but the recyclability is reduced due to contamination
Solution Approach 1:
The first size reduction process performs a preliminary liberation of plastic materials from battery components under immersion conditions, which suppresses dust and contains the process. This preliminary action separates plastics from the bulk of contaminants, so that the second size reduction process requires less energy to achieve the final separation, maintaining low overall energy consumption while ensuring high recyclability.
Solution Approach 2:
The patent uses an immersion environment in the first size reduction process that creates a controlled atmosphere, suppressing dust generation and containing potential thermal runaways. This inert-like environment allows the process to proceed with lower energy input for dust suppression and safety measures, while still achieving effective material liberation and separation that ensures high recyclability.
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 effectively separates plastic materials from metals and black mass, improving the recyclability of plastics and reducing contamination, thereby enhancing the overall efficiency of the recycling process.
Implementation Method 1
heat generated by the size reduction is absorbed by the immersion liquid
Implementation Method 2
carrying out a non-immersion second size reduction of the plastics slurry
Implementation Method 3
utilizing a plastic separator tank with a movable agitator to enhance precipitation
Implementation Method 4
separating the size-reduced plastic material from the size-reduced metal material and black mass
Implementation Method 5
accompanied by mechanical washing and separation to isolate plastics from metals and black mass
Data Source
AI summary
A method of separating plastic material from battery materials can include: a) receiving battery materials in an immersion comminuting apparatus; b) by carrying out at least a first size reduction of the battery materials under immersion to create a primary-reduced metal material, primary-reduced plastic material and liberating a first amount of a black mass material; c) extracting at least a primary plastics slurry from the primary comminuting apparatus, wherein the primary plastics slurry comprises a mixture of the primary-reduced plastic material, a portion of the primary-reduced metal material and a portion of the black mass material liberated by the immersion comminuting apparatus; and d) carrying out a further, second size reduction of the plastic slurry using a non-immersion comminuting apparatus that is downstream from the immersion comminuting apparatus.