Recycled NCA Cathode Material from Spent Battery Leachate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for preparing positive electrode active materials for secondary batteries, such as those described in Korean Patent No. 10-1440241, face high manufacturing costs and environmental unfriendliness due to the use of Ni-rich materials synthesized through co-precipitation, without effectively utilizing spent batteries.
Innovation Solution
A positive electrode active material is prepared using a spent battery leachate with a composition of Li(NiaCobAlc)O2, incorporating Ni, Co, and Al, and optionally Na, Al, Fe, Cu, Zn, Mg, Ca, and Mn, through a process involving acid treatment, impurity removal, and sintering to create a precursor, which is then reacted with an ammonia chelating agent and basic solution to form the active material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Ni-rich positive electrode active material is synthesized through co-precipitation of hydroxide salt, then high capacity characteristics are achieved, but manufacturing costs increase and environmental friendliness deteriorates
Solution Approach 1:
The patent recovers nickel and cobalt metals from spent battery leachate through precipitation and filtration processes, transforming waste materials into valuable precursors for new positive electrode active materials. This circular approach reduces the need for virgin raw materials and decreases manufacturing costs while maintaining high capacity characteristics through controlled co-precipitation of hydroxide salts.
Solution Approach 2:
The patent converts the harmful environmental waste product (spent battery leachate) into a beneficial resource by extracting valuable metals and using them as precursors for synthesizing high-performance positive electrode active materials. The harmful waste stream becomes the foundation for producing materials with high capacity characteristics, simultaneously addressing environmental concerns and reducing manufacturing costs.
2Reliability
If Ni-rich positive electrode active material is synthesized through co-precipitation of hydroxide salt, then high capacity characteristics are achieved, but environmental friendliness deteriorates
Solution Approach 1:
The patent implements a recovery system that extracts nickel and cobalt from spent battery leachate through chemical precipitation and filtration. This process prevents the direct disposal of toxic leachate into the environment while recovering valuable metals that are reused in synthesizing new positive electrode active materials, thereby eliminating environmental harm while maintaining high capacity characteristics.
Solution Approach 2:
The patent transforms the environmentally harmful spent battery leachate into a beneficial resource by using it as the source material for recovering metals and synthesizing high-performance positive electrode active materials. This conversion eliminates the need to treat and dispose of toxic waste while producing materials with high capacity characteristics, simultaneously solving environmental problems and maintaining product performance.
3Manufacturing precision
If spent batteries are not utilized in the synthesis process, then manufacturing quality is maintained, but resource waste increases and environmental impact worsens
Solution Approach 1:
The patent recovers nickel and cobalt metals from spent battery leachate through precipitation and filtration, transforming waste materials into valuable precursors. This process maintains manufacturing precision by controlling the composition and purity of recovered metals, ensuring they meet the specifications required for high-quality positive electrode active materials while maximizing resource utilization.
Solution Approach 2:
The patent controls critical parameters including pH levels during precipitation, temperature during synthesis, and metal ratio in the leachate to ensure the recovered metals maintain the precise composition requirements for high-quality positive electrode active materials. By optimizing these parameters, the patent achieves both high manufacturing precision and effective resource utilization from spent batteries.
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 approach reduces manufacturing costs and environmental impact by recycling spent batteries, maintaining high capacitance and long-term stability while simplifying the preparation process and improving economic feasibility.
Implementation Method 1
a leachate preparation process to prepare a leachate by subjecting valuable metal powders obtained from a spent battery to acid treatment in a reducing atmosphere
Implementation Method 2
an impurity removal process to remove impurities from the leachate
Implementation Method 3
reacting a mixture of the transition metal solution, an ammonia chelating agent, and a basic aqueous solution in a reactor to prepare a precursor of a positive electrode active material
Implementation Method 4
a sintering process to sinter the precursor, the washed precursor, a lithium salt, and an aluminum salt through heat treatment
Data Source
AI summary
Proposed are a positive electrode active material using a spent battery leachate for secondary batteries and a method of preparing the same. Using a spent battery leachate enables the positive electrode active material for secondary batteries, the positive electrode active material having a composition of Li(NiaCobAlc)O2 (where a+b+c=1) including Ni, Co, and Al and being prepared from a precursor having a composition of NiaCob (where a+b=1), to be prepared. As a result, some raw materials can be replaced with the spent battery leachate when preparing the positive electrode active material for secondary batteries, thereby reducing manufacturing costs and solving environmental problems.