Li-Ion Battery Metal Recovery Through Binary Co-Ni Alloy Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pyrometallurgical methods for recovering metals from lithium-ion batteries face challenges in separating valuable metals like cobalt, nickel, and lithium due to the formation of mixed metal alloys, resulting in low recovery rates and energy inefficiency.
Innovation Solution
A method involving soaking waste lithium-ion batteries in a brine solution, followed by mechanical sieving and thermal treatment to separate and extract cobalt, nickel, and manganese compounds, preventing the formation of ternary alloys through controlled smelting with a fluxing agent, and using induction heating for efficient metal recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional pyrometallurgical methods are used to smelt metal contents from lithium-ion batteries, then all metals are recovered in a mixed alloy form, but the recovery rate of valuable metals like lithium, cobalt, and nickel is low due to evaporation and infusion into slag
Solution Approach 1:
The patent divides the smelting process into two distinct stages: first smelting at 1500-1600°C to form a mixed alloy, then performing a second selective smelting at 1200-1300°C to separate and recover specific valuable metals like lithium, cobalt, and nickel. This segmentation allows controlled recovery of individual metals rather than losing them to evaporation or slag infusion in a single high-temperature step.
2Productivity
If conventional pyrometallurgical smelting is used, then all metal contents are recovered together, but the process forms a mixed metal alloy making separation of valuable metals difficult
Solution Approach 1:
The patent implements a two-stage smelting process that segments the metal recovery operation. The first stage recovers base metals in a mixed alloy, while the second stage selectively smelts at lower temperatures (1200-1300°C) to separate and recover precious metals like lithium, cobalt, and nickel in purer forms, thus achieving both productivity and manufacturing precision.
Solution Approach 2:
The patent applies different temperature conditions to different stages of the smelting process. The first stage uses high temperature (1500-1600°C) for general metal recovery, while the second stage uses controlled lower temperature (1200-1300°C) for selective recovery of specific valuable metals, creating local quality differences in the recovery process that enable separation of metal fractions.
3Quantity of substance
If high temperature smelting is used to recover all metals, then the process is energy intensive, but low temperature processing fails to separate metals effectively
Solution Approach 1:
The patent segments the energy-intensive smelting process into two stages with different temperature requirements. The first stage uses high energy input at 1500-1600°C for initial metal recovery, while the second stage uses reduced energy input at 1200-1300°C for selective separation, thereby achieving effective metal separation while reducing overall energy consumption compared to continuous high-temperature smelting.
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 method achieves high recovery efficiency of cobalt and nickel metals in binary alloy form, with over 98% recovery and reduced energy consumption, while preventing the formation of ternary alloys and minimizing lithium loss.
Implementation Method 1
waste lithium-ion batteries are soaked in brine solution for a predetermined time period to obtain discharged batteries
Implementation Method 2
The obtained fine particles are heated at a temperature in the range of 700° C. to 900° C. for a time period in the range of 45 minutes to 90 minutes to reduce some of the compounds from the second mixture
Implementation Method 3
it is smelted by using a fluxing agent at a temperature in the range of 1455° C. to 1550° C. to obtain a smelted mixture comprising a manganese-rich slag and a melt of cobalt (Co) and nickel (Ni) alloy
Implementation Method 4
using induction heating for efficient metal recovery
Data Source
AI summary
The present disclosure relates to a method for the recovery of metals and metal alloys from waste Lithium-ion batteries. The method of the present disclosure uses a smelting process that is energy-efficient, cost-effective and requires comparatively reduced time. Further, the method of the present disclosure has a high metal extraction efficiency. Furthermore, the heat treatment of the residual particulate matter results in the formation of binary Co—Ni alloy and prevents the formation of Co—Ni—Mn ternary alloy during smelting.