Spent Cathode Thermal Recycling for Powder Recyclate Quality
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Solution Overview
Problem
The rapid growth of lithium-ion battery demand for electric vehicles and grid storage leads to a need for efficient recycling methods to process spent cathode materials, particularly lithium iron phosphate, to reduce mining impacts, recover valuable metals like cobalt and nickel, and ensure a constant supply of cathode materials.
Innovation Solution
A method involving thermal treatment, specifically drying and calcination, of spent cathode materials and raw materials in a processing arrangement to produce a cathode material recyclate in powder form, which can be reused directly or mixed with new materials for further processing, reducing the need for new raw material extraction and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If spent cathode material is recycled through thermal treatment to produce cathode material recyclate, then the demand for new raw materials and energy consumption are reduced, but the process complexity and equipment requirements increase
Solution Approach 1:
The patent applies parameter changes by controlling thermal treatment parameters (temperature, residence time, atmosphere) to transform spent cathode material into recyclate with desired properties. The process uses specific temperature ranges and treatment conditions to achieve material regeneration while managing process complexity through parameter optimization rather than additional equipment
Solution Approach 2:
The patent implements discarding and recovering by collecting spent cathode material from end-of-life batteries, processing it through thermal treatment to recover valuable materials, and returning the recyclate to production. This closed-loop approach reduces demand for new raw materials while establishing a systematic recovery process
2Manufacturing precision
If spent cathode material undergoes thermal treatment to produce powder form recyclate, then the recyclate quality and reusability are improved, but the energy consumption increases
Solution Approach 1:
The patent optimizes energy consumption by carefully controlling thermal treatment parameters including temperature profiles, residence time, and atmospheric conditions. These parameter changes enable production of high-quality powder form recyclate while minimizing energy input through efficient process design and parameter selection
3Object-affected harmful factors
If spent cathode material is processed to recover valuable metals, then the environmental impact is reduced, but the processing time and productivity are affected
Solution Approach 1:
The patent implements an integrated recovery process that simultaneously achieves environmental protection and maintains productivity. Spent cathode material is processed through thermal treatment to recover valuable metals and produce usable recyclate in a single continuous process, reducing environmental impact without requiring multiple separate processing steps that would extend processing time
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 enables the efficient recycling of cathode materials, reducing environmental impact and the demand for costly metals like cobalt and nickel, while ensuring a sustainable supply of cathode materials for lithium-ion batteries by producing high-quality recyclates that can be used in electrode coating and paste production.
Implementation Method 1
thermally treating and converting the first liquid substance and the second liquid substance into a cathode material recyclate
Implementation Method 2
thermally treating and converting the first liquid substance and the second liquid substance into a cathode material recyclate in at least one treatment zone of the processing arrangement
Data Source
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AI summary
The invention relates to a method for processing spent cathode material (200) from used lithium-ion batteries and/or cathode reject material (200.1) from defective and unused lithium-ion batteries to produce a cathode material recyclate (300), wherein the method comprises the following steps: - feeding a raw material (100) of a cathode material as a first liquid substance into an arrangement (1), - feeding a spent cathode material (200) and/or cathode reject material as a second liquid substance into the arrangement (1), - thermal treatment and conversion of the first liquid substance and the second liquid substance into the cathode material recyclate (300) in at least one thermal treatment zone (6) of the arrangement (1), and - discharge of the cathode material recyclate (300) in powder form from the arrangement (1).