Electrically Conductive Membrane Filtration for Battery Metal Separation
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Solution Overview
Problem
Current methods for recycling battery components, such as lithium, cobalt, manganese, and nickel, are suboptimal due to high capital and operating costs, and significant environmental impact, particularly due to chemical precipitation and thermal crystallization processes.
Innovation Solution
A system and method utilizing an electrically conductive membrane filter 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 without the need for chemical precipitation, thermal crystallization, or solvent exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chemical precipitation techniques are used to separate battery materials, then separation can be achieved, but contamination occurs and extraction of lithium becomes difficult due to residual sodium and other chemicals
Solution Approach 1:
The patent replaces chemical precipitation methods with an electrochemical membrane separation system. The system uses an electrically conductive membrane filter with applied electric potential to separate battery materials through electrochemical reactions and selective ion transport, eliminating the need for chemical precipitants and avoiding contamination from residual chemicals.
Solution Approach 2:
The patent introduces an electrically conductive membrane as an intermediary separation medium. This membrane acts as a selective barrier that allows certain ions to pass through while blocking others, enabling clean separation without direct contact between materials that would cause chemical contamination.
2Manufacturing precision
If thermal crystallization and solvent extraction are used for material separation, then further purification can be achieved, but capital cost and operating cost increase significantly
Solution Approach 1:
The patent combines separation and purification into a single electrochemical membrane process, eliminating the need for multiple sequential steps including thermal crystallization and solvent extraction. This integrated approach reduces both capital equipment requirements and operating complexity while achieving high purification levels.
Solution Approach 2:
The patent changes the separation mechanism from thermal and chemical processes to electrochemical processes by applying electric potential across the membrane. This parameter change enables separation at lower temperatures and eliminates the need for complex solvent extraction systems, reducing both capital and operational complexity.
3Quantity of substance
If conventional battery recycling methods are used, then critical materials can be recovered, but environmental impact increases due to acid usage and chemical processing
Solution Approach 1:
The patent replaces acid-based chemical leaching and precipitation with electrochemical membrane separation. This substitution eliminates the generation of harmful chemical waste streams while maintaining efficient recovery of critical battery materials such as lithium, cobalt, and nickel.
Solution Approach 2:
The patent converts the harmful effect of acid usage into a benefit by using electrochemical reactions that do not require strong acids. The system achieves material dissolution and separation through controlled electrochemical processes, transforming a polluting process into an environmentally friendly operation.
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 system achieves efficient and cost-effective separation of critical materials, reducing environmental impact and enabling recycling of up to 50% of the acid used, while minimizing contamination and improving the selectivity and yield of valuable metals.
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
The system achieves efficient and cost-effective separation of critical materials... improving the selectivity and yield of valuable metals
Implementation Method 3
a membrane filter comprising a nanoporous structure
Implementation Method 4
The membrane filter is configured to separate a component from a mixture solution. In some examples, the component may be separated into a permeate solution
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.