Cathode Active Material Recovery via Selective Precipitation
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Solution Overview
Problem
There is a need for improved methods to recover and repurpose spent lithium-ion batteries, particularly in preparing cathode active materials from recycled feedstocks to achieve comparable or improved battery performance.
Innovation Solution
A method involving a mixed metal composition comprising nickel, cobalt, manganese, or their combinations, with additional compounds like Cu, Fe, Mg, Na, Ca, Zn, F, Si, or Li, is contacted with water to form a solution, then combined with a salt and a basic solution to precipitate a purified mixed metal composition, which is subsequently lithiated and heat-treated to form a cathode active material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recycled feedstock is used to prepare cathode active materials, then environmental sustainability and cost are improved, but material purity and battery performance may deteriorate
Solution Approach 1:
The patent extracts and removes impurities from recycled cathode materials through a multi-step process: acid leaching to dissolve metals, filtration to remove solids, and controlled precipitation to separate pure metal hydroxides from solution. This extraction process isolates the valuable nickel, cobalt, and manganese from contaminants like aluminum and iron, achieving both recycling and purification goals
Solution Approach 2:
The patent employs parameter changes by adjusting pH levels during precipitation steps to selectively precipitate different metal hydroxides at specific pH ranges. By controlling pH parameters, the process separates metals based on their solubility characteristics, transforming the mixed recycled material into pure components suitable for battery manufacturing
2Loss of substance
If high percentages of recycled feedstock are used, then waste reduction and cost savings are improved, but consistency and quality control may worsen
Solution Approach 1:
The patent achieves homogeneity by converting diverse recycled materials (spent batteries, manufacturing scrap) into a uniform intermediate form (metal hydroxide precipitates). All input materials undergo the same chemical treatment and precipitation process, producing consistent pure metal hydroxide products with controlled composition ratios, regardless of their original heterogeneous forms
Solution Approach 2:
The patent systematically recovers valuable metals from recycled feedstock by discarding impurities. The process selectively retains nickel, cobalt, and manganese while removing contaminants like aluminum, iron, and other unwanted elements, transforming waste materials into high-purity recovered metals suitable for battery production
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 the production of cathode active materials with discharge capacities exceeding 200 mAh/g at a C/3 rate for 100 cycles, comparable to those made from virgin materials, utilizing high percentages of recycled feedstocks, thus addressing the challenge of battery material recycling.
Implementation Method 1
contacting a mixed metal composition with water to form a first solution
Implementation Method 2
combining the second solution and a basic solution to form a precipitate
Implementation Method 3
heat-treating the mixture to form the cathode active material
Data Source
AI summary
A method of making a cathode active material includes contacting a mixed metal composition with water to form a first solution. The mixed metal composition includes nickel, cobalt, manganese, aluminum, or a combination thereof, and greater than 0 to 2 weight percent, based on the total weight of the mixed metal composition, of a compound comprising Cu, Fe, Mg, Na, Ca, Zn, F, Si, Li, or a combination thereof. A salt of nickel, cobalt, manganese, aluminum, or a combination thereof is added to the first solution to provide a second solution, which can be further combined with a basic solution to provide a precipitate. The precipitate can be combined with a lithium compound and treated to provide the cathode active material.