Electrically Conductive Membrane Filtration for Clean Lithium Separation
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Solution Overview
Problem
Current battery recycling methods are suboptimal due to high capital and operating costs, and significant environmental impact, particularly in the extraction of critical materials like lithium, cobalt, manganese, and nickel, which often result in contamination and inefficient separation processes.
Innovation Solution
A system and method utilizing an electrically conductive membrane with a nanoporous structure, an electrical contact, and a counter electrode to generate an electric field, allowing for the separation of components from a mixture solution, such as black mass leachate, through electro-filtration or electro-extraction, minimizing chemical precipitation and solvent exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chemical precipitation techniques are used to separate critical materials from black mass leachate, then separation can be achieved, but the black mass becomes contaminated with residual sodium and other chemicals, making lithium extraction difficult
Solution Approach 1:
The patent replaces chemical precipitation methods with an electro-filtration system that uses electric fields and nanoporous membranes to separate ions from solution. This mechanical/electrical approach avoids the chemical contamination inherent in precipitation methods using sodium compounds and other chemicals, enabling clean separation of lithium and other critical materials without residual contamination.
Solution Approach 2:
The patent employs nanoporous membranes with controlled pore sizes to physically filter and separate ions from the black mass leachate. These porous structures allow selective passage of ions based on size and charge, achieving high separation efficiency without the chemical contamination associated with traditional precipitation techniques.
2Quantity of substance
If traditional battery recycling methods including grinding, leaching, and multiple chemical processing stages are used, then critical materials can be extracted, but capital cost and operating cost are high
Solution Approach 1:
The patent extracts and removes unnecessary chemical processing stages from the traditional recycling workflow. By directly applying electro-filtration to the black mass leachate, the system eliminates intermediate steps such as chemical precipitation, solvent extraction, and thermal crystallization, thereby reducing both capital expenditure on equipment and operating costs for chemicals and energy while maintaining high extraction yields.
Solution Approach 2:
The patent implements a continuous electro-filtration process that maintains constant separation action throughout operation. The electro-filtration system operates continuously to separate lithium and other critical materials from the leachate solution, eliminating the batch processing nature of traditional methods and improving overall process efficiency and cost-effectiveness.
3Manufacturing precision
If traditional battery recycling methods including solvent extraction and thermal crystallization are used, then further separation and purification can be achieved, but environmental impact increases
Solution Approach 1:
The patent replaces environmentally harmful chemical processes (solvent extraction and thermal crystallization) with an electro-filtration system that uses electric fields and nanoporous membranes. This substitution eliminates the need for organic solvents and high-temperature processing, significantly reducing environmental impact while achieving equivalent or superior purification levels for critical materials.
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 approach enables efficient, low-cost, and environmentally sustainable extraction of critical materials by selectively separating components based on charge and size, reducing contamination and operational costs, and allowing for the recycling of acids and retentate solutions.
Implementation Method 1
The membrane filter, via the electrical contact, and the counter electrode are configured to generate an electric field between the membrane filter and the counter electrode
Implementation Method 2
separating components based on charge and size
Data Source
AI summary
The present disclosure relates to systems and methods for electrically conductive membrane separation from a mixture solution via membrane nanofiltration, electro-filtration, or electro-extraction by: generating an electric field at the membrane filter, holding the membrane filter at a constant electric potential, or driving a constant current through the membrane filter; feeding a mixture solution through the membrane nanofiltration system; and separating a component from the mixture solution into a permeate solution.