Li-Ion Cathode Recycling by Low-Temperature Co-Precipitation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional lithium-ion battery recycling methods require high-temperature processes to separate and recombine desirable materials like cobalt, manganese, and nickel, which are energy-intensive and costly, and cannot effectively recycle batteries with mixed chemistries.
Innovation Solution
A low-temperature solution is used to precipitate desirable materials like cobalt, manganese, and nickel in a predetermined ratio without separating them, allowing for the production of active cathode materials for new batteries by maintaining the materials in a commingled state and adjusting pH with sodium hydroxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-temperature processes are used to separate and recombine desirable materials, then manufacturing precision of separated materials is improved, but use of energy increases significantly
Solution Approach 1:
The patent changes the temperature parameter from high-temperature pyrolysis to low-temperature aqueous processing, and changes the separation mechanism from thermal decomposition to chemical dissolution and precipitation, achieving material separation without high energy input while maintaining precision through controlled pH and chemical reactions
Solution Approach 2:
The patent replaces the mechanical/thermal separation system with a chemical system using aqueous solutions, acids, bases, and precipitants to separate and recover metals, substituting high-energy thermal processes with low-energy chemical reactions
2Quantity of substance
If conventional high-temperature separation methods are used, then material recovery is achieved, but device complexity and processing cost increase
Solution Approach 1:
The patent combines multiple separation steps into a single aqueous extraction process where all desirable materials (Co, Ni, Mn, Li) are dissolved together in one solution and then precipitated together as a mixed hydroxide, eliminating the need for separate high-temperature processing lines for each metal and simplifying the overall device complexity
Solution Approach 2:
The patent creates a universal processing system that can handle mixed battery chemistries (NMC, NCA, LCO) through a single aqueous extraction approach, making the process applicable to various battery types without requiring different high-temperature separation equipment for each chemistry
3Manufacturing precision
If high-temperature processes are used for material separation, then purity of separated materials is improved, but loss of energy increases
Solution Approach 1:
The patent utilizes phase transitions of metals from dissolved ionic state to solid precipitate state through pH-controlled hydroxide formation, achieving pure material recovery through controlled precipitation and filtration without the energy-intensive high-temperature melting and crystallization processes
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 achieves high recovery efficiency and reduces environmental impact and costs by recycling lithium-ion batteries, providing a cost-effective and efficient supply of active cathode materials for new batteries.
Implementation Method 1
A strong base, such as sodium hydroxide, raises the pH such that the desired materials precipitate out of solution
Implementation Method 2
the desired materials precipitate out of solution without extensive heating or separation of the desired materials into individual compounds or elements
Data Source
AI summary
Cathode material from exhausted lithium ion batteries are dissolved in a solution for extracting the useful elements Co (cobalt), Ni (nickel), Al (Aluminum) and Mn (manganese) to produce active cathode materials for new batteries. The solution includes compounds of desirable materials such as cobalt, nickel, aluminum and manganese dissolved as compounds from the exhausted cathode material of spent cells. Depending on a desired proportion, or ratio, of the desired materials, raw materials are added to the solution to achieve the desired ratio of the commingled compounds for the recycled cathode material for new cells. The desired materials precipitate out of solution without extensive heating or separation of the desired materials into individual compounds or elements. The resulting active cathode material has the predetermined ratio for use in new cells, and avoids high heat typically required to separate the useful elements because the desired materials remain commingled in solution.