Patent Description:
Energy storage devices, and particularly rechargeable batteries such as lithium ion batteries (LIBs), are in high demand in consumer electronics and electric vehicles. LIBs have been significant such that they have become the most popular power source for portable electronics equipment. LIBs are used for a growing range of applications, as their capacity and charging rates are increased.

This increased demand has greatly stimulated LIBs production, which subsequently has led to greatly increased quantities of spent LIBs, which will have to be treated by suitable processes. Therefore, considerable efforts are underway to minimize environmental pollution and recover battery components.

It is usually not easy to achieve high recovery of valuable metals (i.e., cobalt, lithium, nickel, manganese, copper, aluminum, and iron) from LIBs.

There is a need for an efficient method to recover valuable metals from spent LIBs. Recycling of spent LIBs enhances environmental protection and enhances a circular economy by separating the valuable metallic constituents into different product.

<CIT> discloses a method for recycling lithium during the preparation of lithium batteries.

This invention provides a method for recovering valuable metals from spent lithium ion batteries, the method comprising:.

In an embodiment, the particulate spent lithium ion batteries material obtained in step (b) has a grain size of between <NUM>-<NUM> or between <NUM>-<NUM>.

In an embodiment, the predetermined temperature of the grinding of the remaining spent LIB to obtain a particulate spent lithium ion batteries material is between <NUM>-<NUM>.

In an embodiment, the separation of plastic matrix from the particulate spent lithium ion batteries material is done by air separation.

In an embodiment, the lithium carbonate precipitate obtained in step (g) is further dried to obtain a dry lithium carbonate powder.

In an embodiment, the treatment of step (d) of the separated particulate spent lithium ion batteries material with CH<NUM>/air is carried out at a temperature of between <NUM> to <NUM>.

In an embodiment, heating at a predetermined temperature of the lithium carbonate filtrate of step (g) is carried out at a temperature of between of <NUM> to <NUM>.

In an embodiment, the flux for smelting the other valuable metals comprises silica, carbon, calcium oxide, sodium oxide, alumina, iron oxide, or combination thereof.

In an embodiment, treating the residue comprising cobalt, other valuable metals, iron and non-metal impurities with a flux of step (h) is carried out at a temperature in the range of <NUM> to <NUM>.

In an embodiment, the metallic ingots of step (h) comprise non-ferrous metals selected from Cobalt, Nickel, Manganese, Copper, Aluminum, Titanium, Tin, Lead, Zinc, Sodium, calcium, and combination thereof or iron ingots.

The present invention provides a method for recovering valuable metals from spent lithium ion batteries, the method comprising:.

In one embodiment, "spent LIB" refers herein to used/exhausted lithium ion battery mainly comprising a metallic shell, membrane separator, cathode materials (LiCoO<NUM>, LiMn<NUM>O<NUM>, LiFePO<NUM>, Li<NUM>Ti<NUM>O<NUM>, LiNi<NUM>Al<NUM>CO<NUM>O<NUM>, as well as other lithium metal oxides), aluminum foil, anode materials (graphite), copper foil, and organic electrolytes.

The recovered valuable metals may include Cobalt, Nickel, Manganese, Copper, Aluminum, Iron, Titanium, Tin, Lead, Zinc, Sodium, calcium. Examples of the valuable metals obtained by the method of this invention include: Li<NUM>CO<NUM>, Co, TiO<NUM>, Cu, alumina, iron oxide, sodium oxide, calcium oxide.

The term "other valuable metals" refers herein to at least one of Nickel, Manganese, Copper, Aluminum, Titanium, Tin, Lead, Zinc, Sodium or calcium.

The valuable metals are obtained as metallic ingots and can be used as raw material for other products.

In one embodiment, opening the lithium ion battery and removing the coating layer or shell of the battery includes removing the gases therein. The remaining spent LIB is further used in the method of this invention.

The opening of a LIB is done by any known technique known in the art such as described in <NPL>.

The method of this invention comprises grinding the remaining spent lithium-ion-batteries (LIBs) at a predetermined temperature to obtain a particulate spent lithium ion batteries material. In other embodiments, the predetermined temperature used in the grinding step is between <NUM>-<NUM>. In other embodiments, the particulate spent lithium ion batteries material have a grain size of between <NUM>-<NUM>. In another embodiment, between <NUM>-<NUM>. In another embodiment, between <NUM>-<NUM>.

The method of this invention comprises separating from the particulate spent lithium ion batteries material any plastic matrix. In an embodiment, the separation is done by air, wherein the separation is based on different gravity of the material. In another embodiment, the separation is done by any other method known in the art such as described in <NPL>.

A CH<NUM>/air gas mixture refers to a mixture of CH<NUM> in the presence of air or the presence of oxygen.

The method of this invention comprises treating the separated particulate spent lithium ion batteries material with a CH<NUM>/air gas mixture, wherein the partial pressure of CH<NUM> is between <NUM>% to <NUM>% v/v; at a predetermined temperature for carbonization of the lithium to obtain a particulate spent lithium ion batteries material comprising lithium carbonate. In other embodiments, the treatment is carried out at a temperature of between <NUM> to <NUM>. In other embodiments, at a temperature of between <NUM> to <NUM>. In another embodiment, at a temperature of between <NUM> to <NUM>. In another embodiment, at a temperature of between <NUM> to <NUM>. In another embodiment, at a temperature of between <NUM> to <NUM>. In other embodiments, at a temperature of between <NUM> to <NUM>. In other embodiments, at temperature of between <NUM> to <NUM>. In other embodiments, at temperature of between <NUM> to <NUM>. In other embodiments, at temperature of between <NUM> to <NUM>. In other embodiments, at temperature of between <NUM> to <NUM>. In other embodiments, at temperature of between <NUM> to <NUM>. In other embodiments, at temperature of between <NUM> to <NUM>. In other embodiments, at temperature of between <NUM> to <NUM>. In other embodiments, at temperature of between <NUM> to <NUM>.

The CH<NUM>/air gas mixture used in the method of this invention includes a partial pressure of CH<NUM> between <NUM>% to <NUM>% v/v. In another embodiment, a partial pressure of CH<NUM> is between <NUM> % to <NUM>% v/v. In another embodiment, a partial pressure CH<NUM> is between <NUM> % to <NUM>% v/v. In another embodiment, a partial pressure of CH<NUM> is between <NUM>% to <NUM>% v/v. In another embodiment, a partial pressure of CH<NUM> is between <NUM>% to <NUM>% v/v. In another embodiment, a partial pressure of CH<NUM> is between <NUM>% to <NUM>% v/v. In another embodiment, a partial pressure of CH<NUM> is between <NUM> % to <NUM>% v/v. In another embodiment, a partial pressure of CH<NUM> of between <NUM> % to <NUM>% v/v.

In some embodiments, the weight ratio between the carbon used in the method of this invention to the separated particulate spent lithium ion batteries material is from <NUM>:<NUM> to <NUM>:<NUM>. In another embodiment, the weight ratio is from <NUM>:<NUM> to <NUM>:<NUM>. In another embodiment, the weight ratio is from <NUM>:<NUM> to <NUM>:<NUM>. In another embodiment, the weight ratio is from <NUM>:<NUM> to <NUM>:<NUM>. In another embodiment, the weight ratio is from <NUM>:<NUM> to <NUM>:<NUM>. In another embodiment, the weight ratio is from <NUM>:<NUM> to <NUM>:<NUM>. In another embodiment, the weight ratio is from <NUM>:<NUM> to <NUM>:<NUM>. In another embodiment, the weight ratio is from <NUM>:<NUM> to <NUM>:<NUM>. In another embodiment, the weight ratio is from <NUM>:<NUM> to <NUM>:<NUM>.

In some embodiments, the method of this invention provides lithium extraction. In another embodiment, the yield of the lithium extraction is between <NUM>-<NUM>%. In another embodiment, is between <NUM>-<NUM>%.

In some embodiments, the treatment with a CH<NUM>/air gas mixture provides lithium extraction. In another embodiment, the yield of the lithium extraction is between <NUM>-<NUM>%.

In another embodiment, the yield of the non-ferrous metal extraction is above <NUM>%. In another embodiment, the yield of the Non-ferrous metal extraction is above <NUM>%.

The solubility of the Li<NUM>CO<NUM> in the cold water is high. For example, at <NUM>, the solubility of Li<NUM>CO<NUM> is much higher than that of the d-metals, i.e.~<NUM> gm/L (cf. solubility of NiCO<NUM>, <NUM> gm/L). However, the solubility of Li<NUM>CO<NUM> falls to <NUM> gm/L at <NUM>.

The treatment of the separated particulate spent lithium ion batteries material with the CH<NUM>/air mixture at the predetermined temperature results in a carbonization reaction to yield particulate spent lithium ion batteries material comprising lithium carbonate.

The following are possible carbonization reactions which can occur:.

LiCoO<NUM> + <NUM> CH<NUM> (g) + <NUM> O<NUM>(g) => <NUM> Li<NUM>CO<NUM> + Co + H<NUM>O (g)     (<NUM>).

LiCoO<NUM> + <NUM>/<NUM> CH<NUM> (g) + <NUM>/<NUM> CO<NUM> (g) => <NUM>. 5Li<NUM>CO<NUM> + Co + <NUM>/<NUM><NUM>O (g)     (<NUM>).

2LiFePO<NUM> + CH<NUM> (g) + <NUM>. 5O<NUM> (g) => Li<NUM>CO<NUM> + Fe<NUM>O<NUM> + P<NUM>O<NUM> (g) + <NUM><NUM>O (g)     (<NUM>).

Li<NUM>TiO<NUM> + CH<NUM> (g) + 2O<NUM> (g) => Li<NUM>CO<NUM> + TiO<NUM> + <NUM><NUM>O (g)     (<NUM>).

LiNi<NUM>Mn<NUM>Co<NUM>O<NUM> + CH<NUM> (g) => <NUM>. 3Li<NUM>CO<NUM> + <NUM> Co + <NUM> Ni + <NUM>. 3Mn<NUM>O<NUM> + H<NUM>O (g)     (<NUM>).

Following the treatment with cold water (following the treatment with CH<NUM>/air), a slurry is obtained which is filtered to obtain a lithium carbonate filtrate and a residue containing cobalt, iron, other valuable metals, and non-metal impurities. In some embodiments, other valuable metals include, Nickel, Manganese, Copper, Aluminum (i.e. alumina), Iron (i.e. iron oxide), Titanium, Tin, Lead, Zinc, Sodium (i.e. sodium oxide), calcium (i.e. calcium oxide) or combination thereof. In another embodiment, the Aluminum is alumina. In another embodiment, the Iron is iron oxide. In another embodiment, the Sodium is sodium oxide. In another embodiment, the calcium is calcium oxide.

In other embodiment, the non-metal impurities comprise organic binders, hard carbon, plastic case, polymer foil & electrolyte, silica or combination thereof.

The lithium carbonate filtrate is heated at a predetermined temperature to obtain lithium carbonate precipitate sedimentation followed by filtration to obtain lithium carbonate precipitate and a mother liquid.

In another embodiment, the lithium carbonate filtrate is heated to a temperature of between <NUM> to <NUM>. In another embodiment, to a temperature of between <NUM> to <NUM>. In another embodiment, to a temperature of between <NUM> to <NUM>. In another embodiment, to a temperature of between <NUM> to <NUM>. In another embodiment, to a temperature of between <NUM> to <NUM>.

In some embodiments, the lithium carbonate precipitate is further dried to obtain a dry lithium carbonate powder. In other embodiments, the lithium carbonate precipitate or the lithium carbonate powder prepared by the method of this invention is further used as a raw material in the field of ceramics, glass and batteries.

Lithium carbonate is used in the production of ceramics and glass, and of lithium ion batteries. Lithium carbonate is a common ingredient in both low-fire and high-fire ceramic glaze. It forms low-melting fluxes with silica and other materials. Glasses derived from lithium carbonate are useful in ovenware.

The residue containing cobalt, iron, other valuable metal, and non-metal impurities obtained following the filtration of the slurry is treated with a flux for smelting the valuable metal at predetermined temperature to obtain metallic ingots. In another embodiment, the flux comprises silica, carbon, calcium oxide, sodium oxide, alumina, iron oxide, or combination thereof.

Flux is a chemical cleaning agent, flowing agent, or purifying agent. They are used in both extractive metallurgy and metal joining.

In the process of smelting fluxes added to the contents of a smelting furnace or a cupola for the purpose of purging the metal of chemical impurities and of rendering slag more liquid at the smelting temperature. The slag is a liquid mixture of ash, flux, and other impurities.

The role of a flux is typically dual: dissolving the oxides already present on the metal surface, which facilitates wetting by molten metal, and acting as an oxygen barrier by coating the hot surface, preventing its oxidation.

In another embodiment, the metallic ingots comprise non-ferrous metals selected from Cobalt, Nickel, Manganese, Copper, Aluminum, Titanium, Tin, Lead, Zinc, Sodium, calcium and combination thereof or iron ingots.

In another embodiment, the Aluminum is alumina. In another embodiment, the Sodium is sodium oxide. In another embodiment, the calcium is calcium oxide.

In another embodiment, the treatment with the flux is carried out at a temperature of between <NUM> to <NUM>. In another embodiment, the treatment with the flux is carried out at a temperature of between <NUM> to <NUM>. In another embodiment, the treatment with the flux is carried out at a temperature of between <NUM> to <NUM>. In another embodiment, the treatment with the flux is carried out at a temperature of between <NUM> to <NUM>. In another embodiment, the treatment with the flux is carried out at a temperature of between <NUM> to <NUM>.

The metallic ingot prepared by the method of this invention may be used as a raw material metal production and as a dopant in various alloys.

In other embodiments, the "metallic ingot" includes/refers to herein to non-ferrous metals selected from Cobalt, Nickel, Manganese, Copper, Aluminum (i.e. alumina), Titanium, Tin, Lead, Zinc, Sodium (i.e. sodium oxide), calcium (i.e. calcium oxide) and combination thereof or iron ingots. In another embodiment, the Aluminum is alumina. In another embodiment, the Sodium is sodium oxide. In another embodiment, the calcium is calcium oxide.

The method of the present invention may be used in a system comprising:.

wherein the sample comprises a separated particulate spent lithium ion batteries material, and wherein the CH<NUM>/air gas mixture is fed into the reaction chamber, for treating the particulate spent lithium ion batteries material to yield a particulate spent lithium ion batteries material comprising lithium carbonate.

<FIG> is a schematic illustration of a system that may be used in the method of the invention. <FIG> illustrates schematically a system for use in recovering valuable metals from spent lithium ion batteries, in a non-limiting manner, a furnace with temperature control <NUM> which is in contact with the reaction chamber <NUM>. The reaction chamber includes the sample <NUM> (and optionally solid carbon). The sample includes a separated particulate spent lithium ion batteries material as described in the methods of this invention. The sample may be treated with a CO<NUM>/CO/H<NUM>O mixture, wherein the CO<NUM> cylinder <NUM>, CO cylinder <NUM>, CH<NUM> cylinder <NUM> and the water vapor generator <NUM> are connected to the reaction chamber and feed the sample with a CO<NUM>/CO/ H<NUM>O or CH<NUM>/air mixture. The system further comprises a gas cleaning bottle <NUM> for the neutralization of the gases which is connected to the reaction chamber; a gas sampler for GC analysis <NUM> for the gas mixtures which is connected to the gas cleaning bottle <NUM>; a thermocouple <NUM> which is attached to the sample to measure its temperature; optionally additional temperature monitor <NUM> attached to the sample to measure its temperature; a flowmeter <NUM>, connected to the CO and CO<NUM> cylinders to determine their partial pressure to be used; and valves <NUM>, connected to the CO and CO<NUM> cylinders before each flowmeter <NUM>, to determine the flow of the gas.

The furnace with temperature control <NUM> which is in contact with the reaction chamber <NUM> is configured to heat the reaction chamber to a temperature of between <NUM> to <NUM>, for the treatment with the CO<NUM>/CO/H<NUM>O mixture, a temperature of between <NUM> to <NUM> for treatment with the CH<NUM>/air mixture and solid carbon.

As such, those skilled in the art to which the present invention pertains, can appreciate that while the present invention has been described in terms of preferred embodiments, the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures systems and processes for carrying out the several purposes of the present invention.

Carbonization tests with gas mixtures of CO<NUM>/CO /H<NUM>O (not according to the invention) or CH<NUM>/air (according to the invention) or solid carbon (not according to the invention) and cold-water treatment of the obtained products were carried out with the lithium-containing components of the rechargeable lithium-ion batteries. Exposure of the lithium-containing components of the rechargeable lithium-ion batteries was carried out at a temperature of <NUM>-<NUM>.

For the experiments, model mixtures consisting of lithium titanate (Li<NUM>Ti<NUM>O<NUM>), lithium cobalt oxide (LiCoO<NUM>), lithium iron phosphate (LiFePO<NUM>), lithium nickel manganese cobalt oxide LiNixMnyCozO<NUM> (x+y+z=<NUM>), lithium nickel cobalt aluminum oxide LiNixCoyAlzO<NUM> (x+y+z=<NUM>) and lithium phosphate (Li<NUM>PO<NUM>) were used. These substances are used in various types of rechargeable lithium-ion batteries as cathodes or anodes.

Carbonization of model mixtures with CO<NUM>/CO/H<NUM>O or CH<NUM>/air gas mixture were carried out in a temperature-controlled laboratory furnace at <NUM>- <NUM>: test duration was <NUM> hour. The laboratory setup is described in <FIG>.

Powder of the model mixtures was placed in the furnace in a or quarts boat. Prior to heating, the quartz reactor was cleaned under <NUM>/min nitrogen flow, following which the furnace was heated to a given temperature, again under <NUM>/min nitrogen flow. CO<NUM>/CO/H<NUM>O or CH<NUM>/air gas mixture was fed into the reactor after the latter had reached the designated temperature. Possible chemical reactions that occur during carbonization of said separated particulate spent lithium ion batteries material at predetermined temperature.

Li<NUM>Ti<NUM>O<NUM> + CO<NUM> + CO + H<NUM>O → <NUM> Li<NUM>CO<NUM> + <NUM> TiO<NUM>     (<NUM>).

<NUM> LiCoO<NUM> + CO<NUM> + CO + H<NUM>O → <NUM> Li<NUM>CO<NUM> + <NUM> Co     (<NUM>).

<NUM> LiFePO<NUM> + CO<NUM> + CO + H<NUM>O → LiHCO<NUM> + FeHPO<NUM>     (<NUM>).

Li<NUM>PO<NUM> + CO<NUM> + CO + H<NUM>O → LiHCO<NUM> + LiH<NUM>PO<NUM>     (<NUM>).

After cooling under nitrogen flow, the Pyrex glass boat was removed from the furnace. The final product was weighed, and cold water treated. Thereafter, slurry after treatment was filtered. Filtrate was analyzed with ICP MS. Lithium balances of each test were calculated. Lithium extraction yield to the filtrate was evaluated from each lithium balance.

Results are presented in Tables <NUM> and <NUM>.

Carbonization tests with solid carbon and cold-water treatment of the obtained products were carried out with the lithium-containing components of the rechargeable lithium-ion batteries. Exposure of the lithium-containing components of the rechargeable lithium-ion batteries was carried out at a temperature of <NUM>-<NUM>. At temperatures below <NUM>, the extraction of lithium and non-ferrous metals (cobalt and nickel) sharply decreases due to a decrease in the carbon reducing ability. At temperatures above <NUM>, the material was sintered and the extraction of lithium and non-ferrous metals (cobalt and nickel) sharply decreased due to a decrease of the material porosity.

For the experiments, model mixtures consisting lithium cobalt oxide (LiCoO<NUM>), lithium iron phosphate (LiFePO<NUM>), lithium nickel manganese cobalt oxide LiNixMnyCozO<NUM> (x+y+z=<NUM>), and lithium nickel cobalt aluminum oxide LiNixCoyAlzO<NUM> (x+y+z=<NUM>) were used. These substances were used in various types of rechargeable lithium-ion batteries as cathodes or anodes.

Carbonization of model mixtures with solid carbon was carried out in a temperature-controlled laboratory furnace at <NUM>-<NUM>: test duration was <NUM> hours. The laboratory setup is described in <FIG>.

Powder of the model mixtures with solid carbon was placed in the furnace in a alumina boat. Prior to heating, the quartz reactor was cleaned under <NUM>/min nitrogen flow, following which the furnace was heated to a given temperature, again under <NUM>/min nitrogen flow. Nitrogen was fed into the reactor after the latter had reached the designated temperature. Possible chemical reactions that occur during carbonization of said separated particulate spent lithium ion batteries material at predetermined temperature.

LiFePO<NUM> + C + O<NUM> => Li<NUM>CO<NUM> + FePO<NUM> + CO     (<NUM>).

LiCoO<NUM> + C => Li<NUM>CO<NUM> + CO + Co     (<NUM>).

LiFePO<NUM> + C => Li<NUM>CO<NUM> + FePO<NUM>     (<NUM>).

LiNi<NUM>Mn<NUM>Co<NUM>O<NUM> + <NUM>. 3C => <NUM>. 3Li<NUM>CO<NUM> + <NUM> Co + <NUM> Ni + <NUM>. 3Mn<NUM>O<NUM>     (<NUM>).

LiNi<NUM>Al<NUM>Co<NUM>O<NUM> + C => Li<NUM>CO<NUM> + Co + Ni + Al<NUM>O<NUM>     (<NUM>).

LiNi<NUM>Mn<NUM>Co<NUM>O<NUM> + C => Li<NUM>CO<NUM> + CoO + NiO + Mn<NUM>O<NUM>     (<NUM>).

LiNi<NUM>Al<NUM>Co<NUM>O<NUM> + C => 5Li<NUM>CO<NUM> + CoO + NiO + Al<NUM>O<NUM>     (<NUM>).

After cooling under nitrogen flow, the alumina boat was removed from the furnace. The final product was weighed, and cold water treated. Thereafter, slurry after treatment was filtered. Filtrate and precipitate were analyzed with ICP MS. Lithium, cobalt and nickel balances of each test were calculated. Lithium extraction yield to the filtrate and cobalt and nickel extraction yield to the precipitate were evaluated from each balance.

Claim 1:
A method for recovering valuable metals from spent lithium ion batteries, the method comprising:
a) opening a spent lithium ion battery (LIB), and remove its cover;
b) grinding the remaining spent LIB at a predetermined temperature to obtain a particulate spent lithium ion batteries material including particles having a predetermined grain size;
c) separating from said particulate spent lithium ion batteries material any plastic matrix;
d) treating said separated particulate spent lithium ion batteries material with a CH<NUM>/air gas mixture, wherein the partial pressure of CH<NUM> is between <NUM>% to <NUM>% v/v; at a predetermined temperature for carbonization of the lithium to obtain a particulate spent lithium ion batteries material comprising lithium carbonate;
e) treating said particulate spent lithium ion batteries material comprising lithium carbonate with cold water and optionally with CO<NUM>;
f) filtering the slurry obtained in step (e) to obtain a lithium carbonate filtrate and a residue comprising cobalt, iron, other valuable metals, and non-metal impurities;
g) heating said lithium carbonate filtrate at a predetermined temperature to lithium carbonate precipitate sedimentation followed by filtration to obtain lithium carbonate precipitate and a mother liquid; and
h) treating said residue comprising cobalt, iron, other valuable metals, and non-metal impurities of step (f) with a flux at a predetermined temperature to obtain valuable metallic ingots.