Direct Battery Waste Recycling via Staged Binder Decomposition
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Solution Overview
Problem
Lithium-ion batteries generate significant waste during manufacturing, usage, and disposal, posing environmental sustainability concerns and requiring effective recycling methods to recover materials for reuse.
Innovation Solution
A method involving a first heat treatment at 100° C. to 700° C. to decompose at least 80 wt % of the binder, separating the electrode material from the current collector, followed by a second heat treatment at 400° C. to 1,200° C. to produce a regenerated electrode material, along with surface treatments using solvents like citric acid to remove impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional recycling methods (pyrometallurgical or hydrometallurgical) are used, then battery waste can be processed, but the electrode material structure is damaged and commercial-grade recovery is difficult
Solution Approach 1:
The patent applies controlled heat treatment at specific temperature ranges (100-700°C for first heat treatment, 400-1200°C for second heat treatment) to decompose binders while preserving electrode material structure. This parameter control allows selective removal of organic components without damaging the active electrode materials, enabling recovery of commercial-grade materials
Solution Approach 2:
The recycling process is divided into distinct sequential steps: first heat treatment for initial binder decomposition (80-90 wt%), separation of electrode material from current collector, second heat treatment for remaining binder removal (90 wt%+), and surface treatment. This segmentation allows each step to be optimized independently, preserving electrode material integrity while achieving complete binder removal
2Productivity
If complete binder removal is achieved through aggressive processing, then recycling efficiency improves, but electrode material structure is damaged
Solution Approach 1:
The first heat treatment at 100-700°C performs preliminary decomposition of 80-90 wt% of the binder before separation. This preliminary action weakens and removes the majority of organic binding agents, making subsequent complete binder removal easier and less aggressive on the electrode material structure
Solution Approach 2:
The patent uses two distinct heat treatment periods with different temperature ranges and durations. The first period (100-700°C) removes most binders, and the second period (400-1200°C) completes binder removal. This periodic approach allows complete recycling efficiency while maintaining electrode material integrity through controlled, staged thermal processing
3Loss of substance
If high temperature heat treatment is applied to remove all binders, then binder decomposition is complete, but energy consumption increases
Solution Approach 1:
The heat treatment process is segmented into two temperature stages: 100-700°C for initial binder decomposition and 400-1200°C for complete binder removal. This segmentation allows the process to remove 90 wt%+ of binders efficiently without requiring continuously high temperatures, reducing overall energy consumption compared to single-stage high-temperature processing
Solution Approach 2:
The first heat treatment at lower temperatures (100-700°C) performs preliminary binder decomposition, removing the majority of organic materials before the second heat treatment. This preliminary action reduces the binder load for the energy-intensive second heat treatment, thereby reducing total energy consumption while achieving complete binder removal
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 achieves efficient recycling of lithium-ion battery waste, producing commercial-grade electrode materials that can be reused, thereby reducing greenhouse gas emissions, energy consumption, and virgin material usage.
Implementation Method 1
applying a first heat treatment at a temperature of between about 100° C. and about 700° C. to the battery waste, the first heat treatment decomposing at least about 80 wt % of the binder
Implementation Method 2
applying a second heat treatment at a temperature between about 400° C. and about 1,200° C. to the electrode material to produce a regenerated electrode material, the second heat treatment decomposing at least 90 wt % of binder remaining in the electrode material
Implementation Method 3
applying a surface treatment to the electrode material to remove surface coatings and/or surface impurities from the electrode material. In some embodiments, the surface treatment can include applying a solvent to the electrode material
Data Source
AI summary
Embodiments described herein relate to methods of recycling battery waste. In some aspects, a method can include applying a first heat treatment at a temperature of between about 100° C. and about 700° C. to the battery waste, the first heat treatment decomposing at least about 80 wt % of the binder, separating the electrode material from the current collector, and applying a second heat treatment at a temperature between about 400° C. and about 1,200° C. to the electrode material to produce a regenerated electrode material, the second heat treatment decomposing at least 90 wt % of binder remaining in the electrode material to produce a regenerated electrode material. In some embodiments, the method can include applying a surface treatment to the electrode material to remove surface coatings and/or surface impurities from the electrode material. In some embodiments, the surface treatment can include applying a solvent to the electrode material.