Two-Circuit Nickel Cobalt Extraction Process
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Solution Overview
Problem
The traditional three-circuit process for nickel and cobalt extraction in lithium secondary battery manufacturing requires large facilities, high initial investment costs, excessive use of adjuster solutions, and generates significant wastewater, making it inefficient and costly.
Innovation Solution
A two-circuit process that simultaneously extracts nickel and cobalt, skipping the crystallization step, using specific pH ranges and extraction agents like bis(2-ethylhexyl)phosphate and versatic acid, to produce a high-purity nickel/cobalt mixed solution, reducing facility size and chemical consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a three-circuit process is used for nickel and cobalt extraction, then extraction completeness is improved, but facility size and initial investment costs increase
Solution Approach 1:
The patent combines the impurity extraction circuit and cobalt/nickel extraction circuits into a single two-circuit process. The first circuit simultaneously performs impurity removal and cobalt extraction, while the second circuit performs nickel extraction, eliminating the need for separate three-circuit operations and reducing facility size while maintaining extraction effectiveness.
Solution Approach 2:
The patent extracts and removes the crystallization process from the traditional flow sheet, using direct precipitation with calcium hydroxide to form mixed hydroxide precipitates that can be filtered and processed without requiring extensive crystallization facilities, thereby reducing overall facility requirements.
2Reliability
If a three-circuit process is used for nickel and cobalt extraction, then extraction completeness is improved, but initial investment costs increase
Solution Approach 1:
The patent merges multiple extraction circuits into a streamlined two-circuit process, reducing the number of mixer-settler tanks from 45-60 stages to a more compact configuration. This consolidation directly reduces capital investment in equipment while preserving the ability to achieve complete extraction of nickel and cobalt through optimized chemical conditions.
Solution Approach 2:
The patent skips the traditional crystallization process step by using direct precipitation methods with calcium hydroxide adjustment. This eliminates the need for extensive crystallization facilities and associated equipment investment, reducing initial costs while still achieving high-purity product recovery through filtration and washing operations.
3Reliability
If a three-circuit process is used for nickel and cobalt extraction, then extraction completeness is improved, but adjuster solution consumption increases
Solution Approach 1:
The patent combines pH adjustment operations into fewer, more efficient stages. By adjusting pH to 2.0-2.5 in the first circuit and 3.0-3.5 in the second circuit, the process achieves complete extraction with minimal adjuster solution usage, compared to multiple pH adjustments required in the three-circuit process.
Solution Approach 2:
The patent optimizes pH parameters at critical stages: maintaining pH 2.0-2.5 during cobalt extraction in the first circuit, and pH 3.0-3.5 during nickel extraction in the second circuit. These precise parameter controls maximize extraction efficiency while minimizing the volume of adjuster solutions required, achieving complete metal recovery with reduced chemical consumption.
4Reliability
If a three-circuit process is used for nickel and cobalt extraction, then extraction completeness is improved, but wastewater production increases
Solution Approach 1:
The patent consolidates wastewater generation points by merging extraction circuits. The single two-circuit process produces fewer wastewater streams compared to three separate circuits, and the combined wash water from the mixed hydroxide precipitate can be treated and reused, reducing overall wastewater discharge while maintaining complete metal extraction.
5Manufacturing precision
If a crystallization process is added, then product purity is improved, but process costs increase
Solution Approach 1:
The patent skips the traditional crystallization process by using direct precipitation with calcium hydroxide to form mixed hydroxide precipitates. These precipitates are filtered, washed, and converted to carbonates through carbonation, achieving high-purity nickel and cobalt products without the need for energy-intensive crystallization operations, thereby reducing process costs while maintaining product quality.
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 decreases investment costs, minimizes adjuster solution use, and reduces wastewater production, enhancing site utilization efficiency and environmental sustainability in lithium secondary battery production.
Implementation Method 1
a first circuit extraction process of extracting impurities other than magnesium (Mg) in an organic phase from a sulfide containing nickel, cobalt and magnesium using a first extraction agent
Implementation Method 2
a first circuit scrubbing process of stirring the extracted organic phase along with distilled water to recover the extracted nickel and cobalt in an aqueous phase
Implementation Method 3
a first circuit stripping process of recovering impurities contained in the first extraction agent in an aqueous phase
Implementation Method 4
a second circuit extraction process of saponifying a second extraction agent for separation of magnesium of the first circuit process and extracting nickel, cobalt and manganese in an organic phase
Implementation Method 5
a second circuit scrubbing process of stirring the organic phase from the second circuit extraction process along with distilled water and recovering the extracted magnesium in an aqueous phase
Implementation Method 6
a second circuit stripping process of recovering the extracted nickel and cobalt in an aqueous phase and productizing into a mixed liquid form
Data Source
AI summary
The present invention relates to a method for manufacturing a high-purity nickel/cobalt mixed solution for cathode materials by using a two-circuit process, and particularly to a method for manufacturing a high-purity Ni/Co mixed solution for cathode materials by using a two circuit process that adopts a two-circuit process to extract cobalt and nickel in a simultaneous manner and prepare a Ni/Co mixed solution, thereby reducing the investment cost for the manufacturing process and downsizing mixer-settler facilities to maximize the efficiency of site utilization.The present invention skips the crystallization process by using the two-circuit process, so it is possible to solve the problem of increasing the unit product cost due to the additional process cost, prevent an increase in the consumption of the adjuster solution in each mixer-setter tank for pH adjustment and the process costs, and realize eco-friendly effects, such as cutting down the production of the process wastewater.