Graphite Recovery From Li-Ion Batteries Using Water-Based Separation
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Solution Overview
Problem
Existing methods for recycling lithium-ion batteries are inefficient, leading to the loss of valuable materials like graphite and metals, and pose safety risks due to incomplete discharge and thermal recycling, which can result in fires and the release of harmful substances.
Innovation Solution
A method involving comminution of batteries with water to separate graphite-enriched and depleted fractions, followed by mechanical and fluid processing to recover valuable materials, reducing the need for complete discharge and minimizing fire risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are completely discharged before recycling, then safety risks are reduced, but the process becomes extremely time-consuming and energy-intensive
Solution Approach 1:
The patent applies preliminary action by performing comminution and separation processes before complete discharge is achieved. The mechanical breakdown and water-based separation are conducted on batteries that still retain some charge, extracting valuable materials before the discharge process can complete, thereby avoiding the time-consuming full discharge while maintaining safety through controlled mechanical processing
Solution Approach 2:
The invention extracts valuable materials (graphite, metals) from the battery structure through mechanical comminution and water-based separation before complete discharge occurs. This extraction approach removes the hazardous components containing valuable materials from the charged state, allowing recycling to proceed without requiring the time-intensive complete discharge process
2Device complexity
If battery cells are comminuted and transferred directly into wet-chemical process, then processing is simplified, but the amount of material to be processed doubles the wet-chemical load
Solution Approach 1:
The patent segments the material stream before wet-chemical processing by using water-based separation to divide comminuted battery materials into organic and inorganic fractions. This pre-separation concentrates the valuable metals and graphite into a smaller, more manageable fraction that requires less intensive wet-chemical treatment, reducing the overall processing load while maintaining process simplicity
3Productivity
If mechanical separation is performed without complete discharge, then processing time is reduced, but safety risks increase due to potential short circuits and fires
Solution Approach 1:
Water acts as a safety intermediary during mechanical comminution and separation processes. The presence of water suppresses potential thermal runaway reactions, prevents fire hazards from exposed electrolyte, and provides a cooling effect during mechanical breakdown. This allows high-speed processing of charged or partially charged batteries without proportionally increasing safety risks
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 achieves over 95% recovery of valuable materials with reduced energy consumption and minimal hazardous substance release, enhancing safety and efficiency in the recycling process.
Implementation Method 1
the mixture comprising the comminuted batteries and the water is separated into a first aqueous graphite-enriched fraction and a second non-aqueous graphite-depleted fraction
Implementation Method 2
the second non-aqueous graphite-depleted fraction is guided through a separation device, in particular, a zig-zag separator, and separated into a heavy fraction containing particulate components with a bulk density of at least 0.02 kg/m3 and into a light fraction containing particulate components with a bulk density of a maximum of 0.40 kg/m3
Data Source
AI summary
The present invention relates to a process for obtaining graphite, and optionally metals of value, which are preferably selected from at least one of the metals of the first and/or the third main group and/or at least one of the metals from the 7th to 11th secondary group, from lithium-ion batteries. The invention also relates to a corresponding system (71).