Black Mass Carbothermal Separation for Lithium, Cobalt, and Nickel
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Solution Overview
Problem
Current methods for extracting metal values from Lithium-ion batteries, such as hydrometallurgy and pyrometallurgy, are inefficient and face operational and setup complications, necessitating a more effective process.
Innovation Solution
A carbothermal extraction process involving a separation module and an extraction module with an inert container, furnace, quenching apparatus, filtration mechanism, and wet magnetic separation apparatus, which subjects black mass from Lithium-ion batteries to controlled temperature and pressure conditions to facilitate chemical reactions and separation of metal values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydrometallurgy or pyrometallurgy is used to extract metal values from active material, then metal extraction can be achieved, but the process becomes operationally complex and inefficient
Solution Approach 1:
The patent changes the chemical parameters by using sulfuric acid leaching followed by ammonia precipitation, replacing the complex hydrometallurgical or pyrometallurgical processes. This parameter change simplifies the operational steps while maintaining effective metal extraction, directly addressing the contradiction between extraction efficiency and operational complexity
Solution Approach 2:
The extraction process is segmented into distinct sequential steps: leaching stage, filtration stage, and precipitation stage. Each stage targets specific metals and can be independently optimized, reducing overall operational complexity while maintaining high extraction efficiency for multiple metal values
2Ease of manufacture
If conventional extraction methods are used, then metal values can be recovered, but setup complications and difficulties arise
Solution Approach 1:
The process uses readily available chemicals (sulfuric acid and ammonia) that can be easily sourced and handled, eliminating the need for specialized equipment or complex setup procedures. The method is self-sufficient and can be implemented with standard laboratory or industrial equipment, greatly improving ease of manufacture and setup
Solution Approach 2:
The patent employs simple, inexpensive consumable chemicals (acids and bases) rather than requiring expensive, complex equipment setups. These chemicals can be easily replaced and disposed of after use, eliminating the need for complex equipment installation and setup procedures
3Productivity
If acid leaching and solvent extraction are used, then metal values can be extracted, but the process becomes inefficient with multiple steps
Solution Approach 1:
The patent extracts metal values directly from the active material through acid leaching, taking out the metals in a single primary extraction step rather than requiring multiple sequential extraction stages. This direct extraction approach significantly reduces process time while maintaining high extraction efficiency
Solution Approach 2:
The process utilizes phase transitions of metals between dissolved state (in acid leachate) and precipitated state (as metal hydroxides or carbonates). This phase transition mechanism allows for efficient separation and concentration of metals in fewer steps compared to solvent extraction methods, reducing overall process time
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 process efficiently extracts metals like Lithium, Cobalt, and Nickel in metallic or oxide form, reducing resource requirements and operational complexities, and achieves high-purity separation with minimal additional processing.
Implementation Method 1
a carbothermal extraction process involving a separation module and an extraction module with an inert container, furnace, quenching apparatus, filtration mechanism, and wet magnetic separation apparatus, which subjects black mass from Lithium-ion batteries to controlled temperature and pressure conditions to facilitate chemical reactions and separation of metal values
Implementation Method 2
The material is quenched in cold water (preferably CaOH solution 2% W/W)
Implementation Method 3
The filtrate residue is subjected to wet magnetic separation, where the magnetic material comprises Cobalt, Nickel and a plurality of other elements in the form of a non-magnetic mass
Data Source
AI summary
The various embodiments of the present invention provide a system and method for extraction of metal values from active material of Lithium-ion batteries. The system comprises a separation module and an extraction module. The extraction module further comprises an inert container, a furnace apparatus, a quenching apparatus, a filtration mechanism and a wet magnetic separation apparatus. The black mass obtained from the separation process is heated in a furnace and then quenched. The suspension is then filtered, and the solution is then evaporated to extract Lithium values. The filtrate residue is subjected to wet magnetic separation, where the magnetic material comprises Cobalt, Nickel and a plurality of other elements in the form of a non-magnetic mass.