Electrically Conductive Membrane Filtration for Cleaner Lithium Recovery
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Solution Overview
Problem
Current battery recycling methods are suboptimal in terms of capital cost, operating cost, and environmental impact, particularly due to chemical precipitation and thermal crystallization, which contaminate lithium extraction and require high chemical and thermal inputs.
Innovation Solution
An electrically conductive membrane separation system using a nanoporous membrane filter with an electrical contact and counter electrode to generate an electric field, allowing for selective separation of ions like Li, Co, Ni, and Mn from acidic solutions without significant chemical or thermal processing.
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 the black mass becomes contaminated with residual sodium and other chemicals making lithium extraction difficult
Solution Approach 1:
The patent replaces chemical precipitation processes with an electrochemical membrane system that uses electrical fields and selective ion transport through nanoporous membranes to separate battery materials. This substitution eliminates the need for chemical reagents like sodium compounds, preventing chemical contamination while achieving high-purity separation of lithium from the black mass leachate
Solution Approach 2:
The patent introduces an electrochemical membrane as an intermediary component between the black mass leachate and the separation process. The membrane's nanoporous structure and electrochemical properties enable selective ion transport, allowing lithium to be separated without direct contact with contaminating chemicals, thus maintaining high purity while avoiding harmful chemical interactions
2Manufacturing precision
If solvent extraction and thermal crystallization are used for further separation and purification, then material purity can be enhanced, but capital cost and operating cost increase significantly
Solution Approach 1:
The patent merges multiple separation functions into a single electrochemical membrane system that combines size-based filtration through nanoporous structures with charge-based separation through electrochemical fields. This integration eliminates the need for separate solvent extraction and thermal crystallization units, reducing device complexity while maintaining high material purity through the unified membrane separation process
Solution Approach 2:
The patent changes the separation mechanism from chemical and thermal parameters to electrochemical parameters. By applying electrical potentials across the membrane and controlling ion transport through electrochemical reactions, the system achieves high-purity separation without requiring the complex infrastructure of solvent extraction facilities or thermal crystallization equipment, thereby reducing both capital and operating costs
3Productivity
If strong acids and neutralizing agents are used in the leaching process, then battery materials can be extracted, but environmental impact and chemical usage increase
Solution Approach 1:
The patent implements a system where the electrochemical membrane not only separates lithium from the black mass leachate but also enables recovery and recycling of the acidic leaching solution. The membrane's selective ion transport allows the acid to be regenerated and reused, reducing chemical waste and environmental impact while maintaining high extraction efficiency for battery 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 method reduces capital and operating costs, minimizes chemical and thermal usage, and enhances the selectivity and yield of valuable metal extraction, particularly lithium, while reducing environmental impact.
Implementation Method 1
a membrane filter comprising a nanoporous structure
Implementation Method 2
The membrane filter is configured to separate a component from a mixture solution into a permeate solution
Implementation Method 3
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 4
flow constant current into the membrane filter
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.