Battery Black Mass Leaching Using Copper to Cut Recycling Energy
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Solution Overview
Problem
Current methods for recycling lithium ion battery cathode metal oxides and copper from spent batteries are energy-intensive and costly, often requiring expensive reagents like H2O2 and high-temperature reduction processes, which increase impurity concentrations and decrease recovery efficiency.
Innovation Solution
A process involving reductive leaching of lithium ion battery waste using copper as a reductant at moderate temperatures, followed by high-temperature reduction of a portion of the black mass with solid or gaseous reductants, and subsequent copper recovery through cementation, reducing energy consumption and eliminating the need for expensive reagents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high temperature reduction followed by leaching is used, then metal oxides can be recovered, but energy consumption increases and process cost increases
Solution Approach 1:
The patent changes the temperature parameter from high temperature reduction to moderate temperature reductive leaching (60-90°C), and changes the chemical parameter by using copper as reductant instead of conventional reagents, thereby reducing energy consumption while maintaining recovery efficiency
Solution Approach 2:
Copper acts as an intermediary reductant that facilitates the reduction of higher oxides to lower oxides at moderate temperatures, enabling efficient leaching without requiring high energy input for thermal reduction
2Productivity
If H2O2 is used as reductant, then leaching can be performed, but reagent cost increases and stability decreases
Solution Approach 1:
The patent replaces expensive H2O2 with copper, which is a cheaper and more stable reductant. Copper can be recovered and reused from the leach solution, making it an economical choice compared to single-use H2O2
Solution Approach 2:
Copper is recovered from the leach solution through cementation or other methods and reused as reductant in subsequent batches, creating a self-sustaining system that reduces ongoing reagent costs
3Manufacturing precision
If FeSO4 or Cu is added during leaching, then higher oxides can be reduced, but impurity concentration in leach solution increases
Solution Approach 1:
The patent extracts copper from the anode material and uses it specifically as reductant in the leaching process. After use, copper is recovered from the leach solution through cementation with zinc or other methods, removing it from the impurity stream and enabling its reuse
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 achieves efficient recovery of lithium, nickel, manganese, and cobalt with high purity, reducing energy consumption by 60% and minimizing impurities, enabling cost-effective recycling of lithium ion batteries while allowing for the reuse of copper as a reductant.
Implementation Method 1
reductive leaching of a portion of the black mass of the cathode material with copper and selectively reducing the remaining portion
Implementation Method 2
copper as a reductant to reduce the transition metals
Implementation Method 3
reducing the remaining portion of said black mass of said cathode material at high temperature
Implementation Method 4
recovery of copper by using different cost effective techniques
Data Source
AI summary
A process for recovery of at least one transition metal including selected Ni, Co and Mn and lithium from waste of lithium ion batteries comprising the steps of, subjecting at least a part of said waste of lithium ion batteries including said transition metal in trivalent state to reductive leaching in mineral/organic acids in presence of copper as reductant in the temperature range of 0-100° C. for 5 mins to 12 hrs; and thereafter, following said leaching step by solid liquid separation to remove the undissolved materials to get the clear leach solution of anyone or more of Li, Ni, Co, Mn and Cu for desired recovery therefrom. The process pertains specifically to reductive leaching of a portion of the black mass of the waste lithium ion batteries with copper and selectively reducing the remaining portion of said black mass at high temperature followed by cementation of copper with the metals present in the reduced mass in an energy-efficient and cost-effective technique compared to the conventional high temperature reduction. The reduction step can be avoided by removing the copper from solution either by selective crystallization of copper, or selective Electrowinning of copper or by use of Ni/Co containing scrap.