Battery Waste Decomposition and Separator Compaction
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Solution Overview
Problem
The processing of battery waste, particularly lithium-ion batteries, faces challenges in efficiently separating and recycling valuable materials due to the generation of lightweight and heavyweight portions during mechanical decomposition, which can cause clogging and disrupt plant operations, especially when thermal pretreatment is involved.
Innovation Solution
A system and method that includes a decomposing device to mechanically decompose battery waste into strip-shaped or flake-shaped lightweight and heavyweight portions, a separating unit to spatially separate these portions, and a fiber compactor unit to compact the lightweight portion, allowing for the effective separation and further processing of metals and plastics without chemical or thermal disintegration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal pretreatment is performed to remove electrolytes before mechanical processing, then the battery waste can be processed more safely, but the separator is burned and causes clogging in tubes and conveyor lines
Solution Approach 1:
The system separates the treatment of different components: thermal pretreatment is applied selectively to remove electrolytes from certain battery types, while mechanical decomposition handles the separation of separator material from electrode foils. The separator is then processed through a specific pathway that prevents clogging by separating it from the main material stream before mechanical processing.
Solution Approach 2:
The separator is extracted and separated from the battery structure during mechanical decomposition, then directed to a separate processing pathway. This extraction prevents the separator from causing clogging in the main conveyor and processing lines, while still allowing it to be processed for recycling.
2Loss of substance
If mechanical decomposition is performed to separate materials, then valuable materials can be recovered, but long polymer-strings are generated that agglutinate and entangle causing production downtimes
Solution Approach 1:
The system uses dynamic control of the mechanical decomposition process to optimize the form of separated materials. By adjusting processing parameters, the separator is broken down into manageable pieces rather than long entangling strings, maintaining continuous operation while achieving effective material separation and recovery.
Solution Approach 2:
A separate processing pathway acts as an intermediary for the separator material, receiving it from the mechanical decomposition unit and processing it independently. This intermediary system prevents the separator from interfering with the main processing line, eliminating production downtimes caused by entanglement while ensuring complete material recovery.
3Loss of substance
If complete batteries with housing are processed, then all valuable materials including metals and active materials can be recovered, but the processing complexity increases due to multiple components
Solution Approach 1:
The processing system is segmented into specialized units, each handling specific battery components: thermal pretreatment for electrolyte removal, mechanical decomposition for separator separation, and specialized pathways for different material types. This segmentation allows complex multi-component batteries to be processed systematically through appropriate stages, maximizing material recovery while managing system complexity through functional specialization.
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 enables a robust and disturbance-free recycling process by preventing clogging, allowing for the efficient separation and reusability of valuable materials, with the lightweight portion being compacted and the heavyweight portion being separated effectively, thereby improving the quality of output fractions and recovering active materials like nickel-cobalt concentrates.
Implementation Method 1
a decomposing device (101) for mechanically decomposing the battery waste (150)
Implementation Method 2
a separating unit (103) for separating the lightweight portion (151) from the heavyweight portion (152)
Implementation Method 3
The fiber compactor unit (104) is configured for compacting the lightweight portion (151)
Data Source
AI summary
Embodiments of the present invention relate to a system for processing battery waste. The system comprises a decomposing device for mechanically decomposing the battery waste to a, in particular strip-shaped or flake-shaped, lightweight portion and a heavyweight portion. The decomposing device comprises an outlet for commonly discharging the lightweight portion and the heavyweight portion. The system further comprises a separating unit for separating the lightweight portion from the heavyweight portion, wherein the separating unit is coupled with the decomposing device for receiving the lightweight portion and the heavyweight portion. The system further comprises a fiber compactor unit, wherein the fiber compactor unit is coupled with the separating unit for receiving the lightweight portion. The fiber compactor unit is configured for compacting the lightweight portion under a separation of a further active material.