Cathode Metal Oxide Nanoparticles via CO2-Derived Oxalic Acid

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Solution Overview

Problem

Existing methods for recycling lithium-ion battery cathodes are energy-intensive and environmentally harmful, and they do not efficiently recover valuable metals while maintaining cost-effectiveness.

Innovation Solution

A method to convert carbon dioxide into oxalate or oxalic acid, which is used to separate transition metals from lithium-ion battery cathodes, forming metal oxide nanoparticles through a direct electrochemical process or using formate as an intermediate, under mild conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional methods are used to recycle lithium-ion battery cathodes, then metals can be recovered, but energy consumption is high and environmental harm occurs

Engineering Contradiction:

Improveenergy consumptionVSAvoidenvironmental harm

Core Design Contradiction:

Loss of energyVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical parameters of the leaching process by using oxalic acid instead of conventional strong acids, and employs electrochemical reduction to generate hydrogen in situ, transforming the reaction conditions to achieve lower energy consumption and reduced environmental harm while maintaining effective metal recovery

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional high-energy mechanical and thermal processing methods with an electrochemical system that uses electrical energy to drive the reduction reactions, thereby reducing overall energy consumption and eliminating the need for harsh chemical environments

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional recycling methods are used, then metals are recovered, but the process is expensive and complex

Engineering Contradiction:

Improveprocess costVSAvoidprocess complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent employs a self-service mechanism where oxalic acid serves dual functions as both the leaching agent and the source of carbon for electrochemical reduction, eliminating the need for separate reducing agents and simplifying the overall process while reducing material costs

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent makes the oxalic acid solution perform multiple functions: it acts as the leaching agent to dissolve cathode materials, provides carbon source for hydrogen generation through electrochemical reduction, and serves as the electrolyte medium, thereby reducing the number of separate chemicals and process steps required

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If conventional leaching methods are used, then metals are dissolved, but recovery efficiency is low

Engineering Contradiction:

Improvemetal recovery efficiencyVSAvoidmetal recovery amount

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent introduces hydrogen as an intermediary substance generated in situ through electrochemical reduction of oxalic acid, which then acts as a reducing agent to facilitate metal precipitation, improving both the efficiency and quantity of metal recovery compared to direct acid leaching alone

Inventive Principle:

Principle #24Intermediary (Mediator)

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 allows for the robust, inexpensive, and environmentally friendly recovery of metals from spent lithium-ion battery cathodes, producing metal oxide nanoparticles that enhance drilling fluids, inks, and fluids for enhanced oil recovery.

Implementation Method 1

converting carbon dioxide into oxalic acid via a direct electrochemical process or via conversion of formate as an intermediate

Methodology Applied

Scientific EffectElectrochemical conversion: Electrolysis

Implementation Method 2

dissolving a cathode material including a metal using a leaching solution including an acidic agent and a reducing agent

Methodology Applied

Scientific EffectLeaching: Solvation

Implementation Method 3

adding a second solution including a member selected from the group consisting of oxalic acid and an oxalate salt to the first solution to precipitate a metal oxalate

Methodology Applied

Scientific EffectPrecipitation: Precipitation

Implementation Method 4

calcining the metal oxalate to form metal oxide nanoparticles

Methodology Applied

Scientific EffectCalcination: Thermolysis

Data Source

PatentUS20250223187A1Preparation of metal oxide nanoparticles from cathodes of lithium-ion batteries

Publication Date: 2025.07.10 ARAMCO INNOVATIONS LLC

AI summary

The disclosure relates to methods to prepare metal oxide nanoparticles (MONs) from the cathodes of lithium-ion batteries (LIBs) and carbon dioxide, and related compositions and systems. Carbon dioxide is converted into oxalate or oxalic acid via a direct electrochemical process or via conversion of formate as an intermediate. The oxalate or oxalic acid formed is then used to separate transition metals from the cathode of the lithium-on batteries and the metals are used to form MONs.