Black Mass Extraction From Spent Li-Ion Batteries Using Microwave Leaching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current recycling methods for spent lithium-ion batteries, such as pyrochemical and hydrometallurgical processes, are energy-intensive, costly, and environmentally unsustainable, failing to effectively recover valuable metals and graphite from black mass.
Innovation Solution
A low-temperature method using an aqueous leaching solvent and microwave radiation to dissolve metals from spent lithium-ion batteries, followed by filtration to separate black mass, which includes graphite and other metals, thereby reducing energy consumption and carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pyrochemical processes are used to recycle spent lithium batteries, then metals can be recovered, but energy costs are high and environmental pollution increases
Solution Approach 1:
The patent changes the temperature parameter from high-temperature pyrochemical processes to low-temperature aqueous leaching (below 100°C), fundamentally altering the energy requirements and chemical mechanisms of the recycling process
Solution Approach 2:
The patent replaces thermal-mechanical pyrochemical processes with chemical leaching processes using aqueous solutions, substituting high-energy thermal mechanisms with lower-energy chemical dissolution mechanisms
2Reliability
If pyrochemical smelting is used, then metals can be extracted, but hazardous gases are produced causing environmental pollution
Solution Approach 1:
The patent converts the harmful high-temperature smelting process into a beneficial low-temperature aqueous leaching process, where the leaching solution selectively dissolves metals without producing hazardous emissions, turning an environmentally harmful process into a clean one
Solution Approach 2:
The patent uses an aqueous leaching environment that is inherently safer and produces no hazardous gases, replacing the oxidative high-temperature atmosphere with a controlled liquid-phase chemical environment
3Reliability
If conventional hydrometallurgical processes are used, then metal yield increases, but energy requirements remain high due to heating leaching solvate
Solution Approach 1:
The patent changes the temperature parameter to below 100°C and uses microwave irradiation instead of conventional heating, fundamentally altering the energy input method and reducing overall energy requirements while maintaining effective metal extraction
Solution Approach 2:
The patent replaces conventional thermal heating with microwave irradiation, using electromagnetic energy to directly heat the leaching solution and accelerate metal dissolution without the energy losses associated with conventional heating methods
4Productivity
If high temperature leaching is used, then metal recovery efficiency improves, but handling hazards increase and process cost increases
Solution Approach 1:
The patent changes the temperature parameter to below 100°C, which maintains effective metal recovery while dramatically reducing the hazards associated with handling hot leaching solutions and the costs of safety measures and energy consumption
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
The method enables efficient, cost-effective recovery of high-purity graphite and valuable metals from spent lithium-ion batteries, suitable for direct reuse in manufacturing, with minimal environmental impact.
Implementation Method 1
microwave radiation can be utilized to reduce the time and energy required to heat the leaching solvent to a suitable temperature
Implementation Method 2
contacting a leaching solvent to a portion of the spent Li-ion battery to obtain a first dispersion
Implementation Method 3
The first dispersion is then filtered to separate undissolved material from a first filtrate
Data Source
AI summary
A method for obtaining a metal salt from a spent lithium-ion (Li-ion) battery may include contacting a leaching solvent to a portion of the spent lithium-ion battery to form a first dispersion. The first dispersion is heated to a temperature in a range from 50° C. to 90° C. by applying microwave radiation. The temperature of the first dispersion is maintained to be in the range from 50° C. to 90° C. for a period in a range from 10 seconds to 5 minutes by further applying microwave radiation to the heated first dispersion. The first dispersion is filtered to obtain a first filtrate. The first dispersion is then filtered to separate undissolved material from a first filtrate. The undissolved precipitate is dehydrated to obtain the black mass.