Black Mass Leach Purification via Copper Cementation and Lime Precipitation
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Solution Overview
Problem
Current lithium-ion battery recycling methods are inefficient in removing impurities from black mass, leading to reduced purity of recovered precious metals and increased equipment usage, resulting in significant loss of valuable materials.
Innovation Solution
A method involving the adjustment of pH in a leaching solution to induce copper cementation using iron powder, followed by the addition of lime to precipitate calcium fluoride, titanium hydroxide, aluminium hydroxide, iron hydroxide, and iron phosphate, effectively removing impurities from the solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional impurity removal methods are used, then impurities are removed from the leaching solution, but the process requires numerous reactors and filters which increases device complexity and causes valuable material loss
Solution Approach 1:
The patent combines multiple impurity removal functions into a single reactor by sequentially adding iron powder for copper cementation, then lime for precipitation of multiple impurities (calcium fluoride, titanium hydroxide, aluminium hydroxide, iron hydroxide, and iron phosphate). This consolidation eliminates the need for numerous separate reactors and filters, reducing device complexity while maintaining high purity recovery of precious metals
Solution Approach 2:
The single reactor is designed to perform multiple functions: copper cementation via iron powder addition, pH adjustment, and precipitation of various impurities through lime addition. This multi-functional approach replaces the conventional multi-reactor system, achieving both simplification and effective impurity removal
2Manufacturing precision
If conventional impurity removal methods are used, then impurities are removed from the leaching solution, but valuable material is lost at each reactor or filter resulting in severe reduction in precious metals available for recovery
Solution Approach 1:
By consolidating all impurity removal operations into a single reactor, the patent eliminates multiple transfer steps between reactors and filters where valuable material loss occurs. The combined process achieves high purity recovery while minimizing material loss through a streamlined, single-stage operation
3Manufacturing precision
If conventional impurity removal methods are used, then impurities are removed from the leaching solution, but the entire recycling process is lengthened
Solution Approach 1:
The patent merges sequential impurity removal steps into a single integrated process within one reactor. By performing copper cementation and multiple precipitation reactions in one vessel rather than through multiple sequential reactors and filters, the overall process time is significantly reduced while maintaining high purity outcomes
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 a significant removal of impurities, with over 90% copper removal and substantial precipitation of other impurities, thereby enhancing the purity of recovered precious metals and reducing equipment requirements.
Implementation Method 1
adding iron powder to induce copper cementation
Implementation Method 2
transiting pH of the leaching solution to about pH 6 to extract calcium fluoride, titanium hydroxide, aluminium hydroxide, iron hydroxide, and iron phosphate
Data Source
AI summary
A method of treating a leaching solution derived from a black mass from spent lithium-ion batteries comprising setting pH of the leaching solution to about pH 1.2 to 2.5, adding iron powder to induce copper cementation, adding lime after copper cementation, and after adding lime, transiting pH of the leaching solution to about pH 6 to extract calcium fluoride, titanium hydroxide, aluminium hydroxide, iron hydroxide, and iron phosphate. A black mass recycling system comprising an impurity removal reactor configured to receive a sodium hydroxide feed, an iron powder feed, and a lime feed.