Cathode-Derived Metal Oxide Nanoparticles for Stable Drilling Fluids
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Solution Overview
Problem
Existing methods for processing spent cathodes of lithium-ion batteries are inefficient, costly, and environmentally unfriendly, and they do not effectively enhance the properties of drilling fluids used in underground drilling operations.
Innovation Solution
A method is developed to convert cathodes of lithium-ion batteries into metal oxide nanoparticles (MONs) using mild conditions, which are then incorporated into drilling fluids to improve rheological properties and reduce fluid loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to process spent cathodes of lithium-ion batteries, then processing can be performed, but the methods are inefficient, costly, and environmentally unfriendly
Solution Approach 1:
The patent changes the parameters of the leaching process by using a mixed acid system (sulfuric acid and hydrochloric acid) with specific concentration ratios, controlling temperature (60-80°C), and adjusting particle size (0.5-2 mm) to achieve high metal recovery efficiency while maintaining environmentally friendly conditions
Solution Approach 2:
The patent employs a composite approach by combining multiple acids in specific proportions (sulfuric acid and hydrochloric acid in 3:1 to 1:3 ratio), and later combines metal oxalate precipitates with calcination to produce high-purity metal oxide nanoparticles with enhanced properties
2Loss of substance
If high metal recovery is achieved from spent cathodes, then valuable metals are recovered, but the process becomes more complex and costly
Solution Approach 1:
The patent performs preliminary classification of spent cathodes by particle size (0.5-2 mm) before leaching, and pre-adjusts the acid concentration ratios based on the specific cathode composition, which simplifies the overall process by preventing downstream separation issues and reducing the need for additional purification steps
Solution Approach 2:
The patent uses metal oxalate as an intermediary compound in the precipitation step, which selectively precipitates different metals (cobalt, nickel, manganese) from the leachate, allowing for simplified sequential recovery without complex separation equipment
3Reliability
If metal oxide nanoparticles are added to drilling fluid, then rheological properties and stability are improved, but the cost of drilling fluid increases
Solution Approach 1:
The patent produces metal oxide nanoparticles from waste spent cathodes themselves, making the drilling fluid additive from the waste material rather than purchasing expensive commercial nanoparticles, thereby reducing costs while maintaining performance
Solution Approach 2:
The patent recovers valuable metals from spent cathodes that would otherwise be discarded, transforming waste into high-value metal oxide nanoparticles for drilling fluid applications, reducing both waste disposal costs and additive purchase costs
4Reliability
If conventional nanoparticles are used in drilling fluid, then fluid properties are enhanced, but the nanoparticles are expensive and difficult to recover
Solution Approach 1:
The patent converts the harmful waste spent cathodes into beneficial metal oxide nanoparticles, and simultaneously converts the challenge of waste disposal into an opportunity for producing cost-effective, recoverable drilling fluid additives
Solution Approach 2:
The patent uses magnetic separation (applying magnetic field) to replace complex mechanical filtration or centrifugation systems for nanoparticle recovery, simplifying the separation process and reducing equipment costs
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 MONs enhance drilling fluid stability under high pressure and temperature conditions, reduce friction, and allow for easy recovery and reuse, providing a cost-effective and environmentally friendly solution.
Implementation Method 1
dissolving a cathode material including a metal using a leaching solution including an acidic agent and a reducing agent to provide a first solution including ions of the metal
Implementation Method 2
adding a second solution including oxalic acid and/or an oxalate salt to the first solution to precipitate a metal oxalate
Implementation Method 3
calcining the metal oxalate to form metal oxide nanoparticles
Implementation Method 4
Due the electronic properties of certain MONs (e.g., cobalt oxide nanoparticles (Co3O4)), the nanoparticles can be relatively quickly and/or easily separated from fluids, for example, through the application of a magnetic field
Data Source
AI summary
The disclosure relates to methods to prepare metal oxide nanoparticles (MONs) from the cathodes of lithium-ion batteries (LIBs), and related compositions and systems. The MONs can be used to improve the properties of drilling fluids, such as those used in underground drilling methods to produce oil and/or natural gas.