AU2025259976A1 - Battery recycling - Google Patents

Abstract

The present invention provides a method for obtaining a cobalt-enriched material, comprising: (a) providing a discharged lithium ion cell comprising cobalt; (b) crushing the cell to form fragments; (c) separating the fragments to obtain particles of less than 4 mm in size; and (d) treating the obtained particles with a magnetic field of between 2000 and 8000 Gauss, so as to select cobalt-enriched material from non-cobalt-enriched material, wherein the method does not comprise a heat treatment, as well as a product obtained from the method, and an apparatus for carrying out the method.

Description

BATTERY RECYCLING BATTERY RECYCLING

Related Application Related Application

[0001] Thepresent

[0001] The presentapplication application is is aa divisional divisionalof ofAustralian AustralianPatent PatentApplication ApplicationNo. No. 2023241377, 2023241377,

whichclaims which claimspriority priority from from Australian Australian Provisional ProvisionalPatent Patent Application ApplicationNo. No.2022902909 2022902909 filed filed on on

66 October 2022,the the entire entire contents contents of of each each of of which is hereby hereby incorporated by reference. reference. 2025259976

October 2022, which is incorporated by

Field Field

[0002] The

[0002] The present present invention invention relates relates tofield to the the field of battery of battery recycling. recycling. More particular, More particular, this this invention relatestotoa amethod invention relates method and and apparatus apparatus for processing for processing cobalt-containing cobalt-containing batteries and batteries and

recovering a cobalt-enriched product. However, it will be appreciated that the invention is not recovering a cobalt-enriched product. However, it will be appreciated that the invention is not

limited tothis limited to this particular particularfield fieldofofuse. use.

Background Background

[0003] The

[0003] The following following discussion discussion of theof the art prior prior is art is provided provided to placeto place the the invention invention in an in an appropriate technical context and enable the advantages of it to be more fully understood. It appropriate technical context and enable the advantages of it to be more fully understood. It

should should bebe appreciated, appreciated, however, however, thatdiscussion that any any discussion of the of the prior artprior art throughout throughout the specification the specification

should not be should not be considered considered as as an an express express or or implied implied admission admissionthat that such suchprior prior art art isiswidely widely known known

or or forms part of forms part of the thecommon generalknowledge common general knowledgein in thethe field. field.

[0004] Asdeveloped

[0004] As developedeconomies economies transition transition away away from from non-renewable non-renewable or “fossil” or "fossil" sources sources of of

energy, theneed energy, the needforfor storing storing energy energy is rapidly is rapidly increasing. increasing. Batteries Batteries based based on onions lithium lithium are ions are

currently thepreferred currently the preferred option, option, as they as they provide provide a number a number of advantages of advantages over other over other chemistries, chemistries,

such as fast such as fast recharging, recharging,aahigh highpower power density density and and being being lightweight, lightweight, making themsuitable making them suitablefor for aa range of applications. For instance, there is a rising demand for electric and hybrid electric range of applications. For instance, there is a rising demand for electric and hybrid electric

vehicles, where lithium-ion batteries are used extensively. Accordingly, the use of lithium-based vehicles, where lithium-ion batteries are used extensively. Accordingly, the use of lithium-based

batteries is growing at an increasing rate. batteries is growing at an increasing rate.

[0005] However,

[0005] However, it isit also is also known known that batteries that batteries have a have a limited limited lifespan,lifespan, with charge- with repeated repeated charge- discharge cycles degrading discharge cycles degradingthe the battery battery components, generallythrough components, generally throughside sidereactions reactionsthat that limit limit the “free” ions in the battery or by introducing structural disorder, which reduces the capacity the "free" ions in the battery or by introducing structural disorder, which reduces the capacity

and lifetimeofofthe and lifetime thebattery. battery.TheThe market market forecast forecast of lithium of lithium ion battery ion battery recycling recycling or resource or resource

recovery as recovery as projected projected to to be be US$10.7 billion by US$10.7 billion by 2026, 2026,with withaa compound compound annual annual growth growth raterate of of about 24.8% about 24.8% during during 2021-2026. 2021-2026. The increasing The increasing use of use of lithium ionlithium ionresults batteries batteries in a results in a price hike price hike

for the raw for the rawbattery batterymaterials materials such such as cobalt as cobalt and lithium, and lithium, thus making thus making battery recycling battery recycling or or recovery industries increasingly more profitable. In addition, limited availability of the raw recovery industries increasingly more profitable. In addition, limited availability of the raw

materials used materials used in in lithium lithium ion ion battery batterymanufacturing and high manufacturing and high demand demandfrom from various various end-use end-use

applications fuels the market for lithium ion battery recycling and resource recovery. applications fuels the market for lithium ion battery recycling and resource recovery. 2025259976

[0006] Currently,

[0006] Currently, batteries batteries rely rely on metallic on metallic elements elements that that are are a finite a finite resource resource obtainedobtained by by miningand mining andmay maybebe environmentally environmentally damaging damaging if disposed if disposed oflandfill. of in in landfill.Therefore, Therefore,ititwould wouldbebe advantageous to able advantageous to be be able to recover to recover such materials such materials from batteries from batteries thatlonger that are no are no longer useful, so useful, so

that they can be re-used in new batteries or for other applications. However, there are limited that they can be re-used in new batteries or for other applications. However, there are limited

commercially-beneficial processesfor commercially-beneficial processes forrecovering recoveringresources resourcesfrom fromspent spentlithium lithiumion ionbatteries. batteries.

[0007] Accordingly,

[0007] Accordingly, there there is a is a need need for a for a suitable suitable methodmethod for processing for processing spent spent lithium ionlithium ion

batteries and batteries and recovering recovering metallic metallic elements elements from them.Preferably, from them. Preferably, the the method would method would bebe atatleast least one of low one of cost, have low cost, have low energyconsumption, low energy consumption,efficient efficientand andeasy easytotooperate. operate.

[0008]

[0008] InInone one aspect, aspect, it it is is anan object object of of thethe present present invention invention that that at at least least one ofone the of the above needs needs above is at least is at leastpartially partially satisfied. satisfied.

[0009]

[0009] InInanother another aspect, aspect, it is it is an an object object of the of the present present invention invention to overcome to overcome or ameliorate or ameliorate one one or moreofofthethedisadvantages or more disadvantages ofprior of the the prior art,atorleast art, or at least provide provide a useful a useful alternative. alternative.

Summary Summary ofofInvention Invention

[00010] In one

[00010] In one embodiment, embodiment, thethe presentinvention present inventionaims aims to to addressatatleast address least one oneof of the the deficiencies of current processes for recycling and/or recovering resources from batteries. In deficiencies of current processes for recycling and/or recovering resources from batteries. In

particular, in one embodiment the present invention aims to reduce the costs (both in terms of particular, in one embodiment the present invention aims to reduce the costs (both in terms of

energy andfinancial energy and financial costs) costs) of of recovering recovering valuable valuable metals metals from used lithium from used lithium ion ion batteries. batteries. More More

particularly, ininone particularly, oneembodiment the present embodiment the present invention invention aims aimsto to produce produceaacobalt-enriched cobalt-enriched material from spent lithium ion batteries, which can then be used to produce new batteries, or material from spent lithium ion batteries, which can then be used to produce new batteries, or

other other useful useful materials. materials.Advantageously, in some Advantageously, in embodiments some embodiments thethe present present invention invention achieves achieves

these aims without the use of a heating step, thereby saving significant energy costs. these aims without the use of a heating step, thereby saving significant energy costs.

[00011]

[00011] InIn a a firstaspect first aspectofofthethe present present invention, invention, therethere is provided is provided a method a method for obtaining for obtaining a a cobalt-enriched material, comprising: cobalt-enriched material, comprising:

(a) (a) providing providing a a discharged discharged lithium lithium ion comprising ion cell cell comprising cobalt; cobalt;

(b) (b) crushing thecell crushing the celltotoform form fragments; fragments;

(c) (c) separating thefragments separating the fragments to obtain to obtain (or provide) (or provide) particles particles of lessofthan less4 than mm in4size; mm in size; and and 2025259976

(d) (d) treating the obtained treating the obtained(or(or provided) provided) particles particles with with a magnetic a magnetic field offield of between between 2000 2000 and 8000Gauss, and 8000 Gauss,sosoasasto to select select cobalt-enriched cobalt-enriched material material from non-cobalt-enrichedmaterial, from non-cobalt-enriched material, whereinthe wherein the method methoddoes doesnot notcomprise comprise a heattreatment. a heat treatment.

[00012] Thefollowing

[00012] The followingoptions optionsmay maybe be used used in in conjunction conjunction with with thethe firstaspect, first aspect, either either individually individually ororininany any suitable suitable combination. combination.

[00013] The

[00013] The lithium lithium ion ion cell cell may may be anybe any suitable suitable electrolysis electrolysis cell or galvanic cell or galvanic cell that cell that comprises comprises

lithium ions.For lithium ions. Forexample, example, the the cell cell may may be located be located in a lithium in a lithium ion battery, ion battery, or it mayor beitlocated may be located in in a a fuel cell, electrolysis fuel cell, device,ororthe electrolysis device, thelike. like.InInone one preferred preferred embodiment, embodiment, the the cell is cell is located located in in aa lithium ionbattery. lithium ion battery.

[00014] The

[00014] The fragments fragments formed formed in stepin step (b) (b) includes includes the particles the particles defined defined in step (c)inand step may(c) and may also also

include largerororsmaller include larger smaller pieces pieces or parts or parts of the of the cell. cell. In other In other words, words, “fragments” "fragments" encompasses encompasses all all solid parts of solid parts of the thecell cell obtained obtained following following the crushing the crushing of(b). of step step (b).

[00015] Theparticles

[00015] The particles obtained obtained from fromthe the separating separating step step (step (step (c)) (c))may may be be less less than thanabout about 44 mm mm

in in size, size, or or less less than about3 3mm,mm, than about or less or less thanthan aboutabout 2 mm, 2ormm, or atabout at least least1.5 about 1.5less mm, or mm, or less than than

about 1.2 mm, about 1.2 orless mm, or less than than about about 11 mm. mm.For Forexample, example, theparticles the particlesthat that are are obtained maybebe obtained may

betweenabout between about3030µmμm andand about about 4 mm, 4 mm, or between or between aboutabout 45 µm45 μm3 and and mm, 3 ormm, or between between about 63about 63 μm andabout µm and about1.2 1.2mm, mm,or or between between about about 100100 μm about µm and and about 2.5 or 2.5 mm, mm, or between between about about 250 µm 250 μm

and and 11 mm, mm,ororthey theymay maybebeanyany othersuitable other suitablesubrange. subrange.

[00016] Anysuitable

[00016] Any suitableororappropriate appropriateseparating separating method methodorordevice devicemay maybe be used used in in theseparating the separating step (step (c)) step (step (c)) to to obtain obtainthe theparticles particlesofofa acertain certain size. size. As As the the skilled skilled person person wouldwould appreciate, appreciate,

whilst particles can be separated on the basis of a range of physical properties (such as, for whilst particles can be separated on the basis of a range of physical properties (such as, for

example, size,density, example, size, density, conductivity conductivity or floatation), or floatation), in order in order to obtain to obtain particles particles within within a defined a defined

size range,itit is size range, is preferred thatsize-based preferred that size-based methods methods or devices or devices by employed by employed in the present in the present

invention. invention. In In some embodiments, some embodiments, thepresent the presentinvention inventionmay may useuse oneone or or more more sieves sieves to to obtain obtain a a

4 31 Oct 2025

fraction withina asize fraction within sizerange range as as defined defined herein. herein. For example, For example, one, one, two, two,four three, three, foursieves or more or more sieves may be used to obtain particles of a certain size. In one embodiment, two sieves are used, may be used to obtain particles of a certain size. In one embodiment, two sieves are used,

whereby one sieve defines an upper range of particle size (and so the particles that pass through whereby one sieve defines an upper range of particle size (and so the particles that pass through

the sieve are collected) and the second sieve defines the lower range of particle size (and so the the sieve are collected) and the second sieve defines the lower range of particle size (and so the

particles that are retained in the sieve are collected). particles that are retained in the sieve are collected).

[00017] Themagnetic magneticfield fieldthat that is is applied applied in in the thetreating treatingstep may maybe bebetween between 2000 Gaussand and 2025259976

[00017] The step 2000 Gauss

8000 Gauss,ororit 8000 Gauss, it may beany may be anysubrange subrangetherein. therein.For Forexample, example,itit may maybebebetween between about about 3000 3000 and and

5000 Gauss,ororbetween 5000 Gauss, betweenabout about2500 2500 Gauss Gauss and and 75007500 Gauss, Gauss, or between or between aboutabout 40006000 4000 and and 6000 Gauss, or it Gauss, or it may may be be about 2000, 2100, about 2000, 2100,2200, 2200,2300, 2300,2400, 2400,2500, 2500,2600, 2600, 2700, 2700, 2800, 2800, 2900, 2900, 3000, 3000,

3100, 3200, 3300, 3100, 3200, 3300,3400, 3400,3500, 3500,3600, 3600,3700, 3700,3800, 3800, 3900, 3900, 4000, 4000, 4100, 4100, 4200, 4200, 4300, 4300, 4400, 4400, 4500, 4500,

4600, 4700, 4600, 4700,4800, 4800,4900, 4900,5000, 5000,5100, 5100,5200, 5200,5300, 5300, 5400, 5400, 5500, 5500, 5600, 5600, 5700, 5700, 5800, 5800, 5900, 5900, 6000, 6000,

6100, 6200, 6300, 6100, 6200, 6300,6400, 6400,6500, 6500,6600, 6600,6700, 6700,6800, 6800, 6900, 6900, 7000, 7000, 7100, 7100, 7200, 7200, 7300, 7300, 7400, 7400, 7500, 7500,

7600, 7700, 7800, 7600, 7700, 7800,7900, 7900,oror8000 8000Gauss, Gauss,ororany anyrange rangetherein. therein.The Themagnetic magnetic fieldmay field maybe be

provided by provided byany anysuitable suitable device. device. In In some embodiments, some embodiments, thethe magnetic magnetic field field may may be be provided provided by aby a magneticseparator, magnetic separator, which whichcomprises comprisesa amagnet magnet (eithera apermanent (either permanent magnet magnet or electromagnet) or an an electromagnet) aa barrier between barrier between thethe magnet magnet andparticles and the the particles (such (such as, for as, for example, example, a drum or aa drum orand plate), a plate), two and two or morecollection or more collection bins bins or areas or areas for for separating separating the particles the particles based based on the strength on the strength of their of their

interaction withthethemagnetic interaction with magnetic field. field. In one In one embodiment, embodiment, the magnetic the magnetic separator separator is is a rotating a rotating

shaft drum.Preferably, shaft drum. Preferably, thethe rotating rotating shaft shaft drum drum has a has a diameter diameter of less of less than than about 30 about 30ascm, such as cm, such

betweenabout between about1515cmcm and and 30 30 cm,cm, or or between between about about 20and 20 cm cm 25 andcm, 25or cm, or about about 10,12, 10, 11, 11, 13, 12, 13, 14, 15, 16, 14, 15, 16, 17, 17,18, 18,19, 19,20, 20,21,21,22,22, 23,23, 24,24, 25,25, 26, 26, 27, 27, 28, 28, 2930orcm.30Incm. 29 or Inembodiments, other other embodiments, the the magnetic field is provided by an eddy current separator, whereby the separation of the particles magnetic field is provided by an eddy current separator, whereby the separation of the particles

is is based ontheir based on theirinteraction interaction with with an eddy an eddy current current (which(which is generally is generally useful useful for for separating separating

conductivenon-ferrous conductive non-ferrousmetals metalsfrom fromnon-conductive non-conductive particles),whereby particles), whereby conductive conductive particles particles are are

ejected fromthethe ejected from particle particle stream stream (usually (usually a conveyor a conveyor belt or belt or theand the like) like) and non-conductive non-conductive

particles pass particles pass through through unaffected. unaffected. In Insome some embodiments, botha amagnetic embodiments, both magnetic separator separator and and an an eddy eddy

current current separator separator may be used may be usedin in series, series, whereby the magnetic whereby the field separator magnetic field separator removes ferrous removes ferrous

materials (that materials (thatmay may damage damage ananeddy eddycurrent currentseparator, separator,asasferrous ferrous materials materials heat heat up in an up in an eddy eddy

current) and the eddy current separator separates conductive, less magnetic materials (such as current) and the eddy current separator separates conductive, less magnetic materials (such as

cobalt). cobalt).

[00018] In some

[00018] In someembodiments, embodiments,thethe treatment treatment step step (step(d)) (step (d))further further comprises comprisesananoptional optional electrostatic separation device, which also separates particles on the basis of conductivity electrostatic separation device, which also separates particles on the basis of conductivity

differences, albeitwith differences, albeit withelectrostatic electrostatic attractive attractive forces forces rather rather thanthan interaction interaction in a magnetic in a magnetic field field

or eddycurrent. or eddy current.TheThe electrostatic electrostatic separator separator may may be usedbe toused treatto treat the the particles particles obtainedobtained after after treatment with a magnetic separator or after treatment with an eddy current separator. treatment with a magnetic separator or after treatment with an eddy current separator.

[00019] Themethod

[00019] The methodof of thepresent the presentinvention inventionmay may furthercomprise further comprise an an optional optional step step of of treating treating

the fragments obtained from step (b) with a solvent before treatment with a magnetic field in the fragments obtained from step (b) with a solvent before treatment with a magnetic field in

step step (c). (c).As Asthe theskilled person personwould would appreciate, appreciate,electrodes electrodesmay may comprise comprise aa polymer binder, 2025259976

skilled polymer binder,

wherebyremoval whereby removalof of atatleast least aa portion portion of of the the polymer binder before polymer binder before particle particle separation separation may may

increase therecovery increase the recoveryof of valuable valuable metals metals from from the the electrodes. electrodes. Accordingly, Accordingly, any solventany thatsolvent at that at least least partially dissolvesorordegrades partially dissolves degradesthe the polymer polymer binderbinder may be may be suitable suitable for this step. for this optional optional In step. In

some embodiments, some embodiments, thethe polymer polymer binder binder may may be polyvinylidene be polyvinylidene fluoride fluoride (PVDF). (PVDF). In such In such

embodiments, suitablesolvents embodiments, suitable solventsmay maybebeselected selectedfrom from dimethyl dimethyl formamide formamide (DMF), (DMF), dimethyl dimethyl

sulfoxide sulfoxide (DMSO), N-methyl-2-pyrrolidone (DMSO), N-methyl-2-pyrrolidone (NMP), (NMP), dimethylacetamide dimethylacetamide (DMAc) (DMAc) or mixtures or mixtures

thereof. In thereof. In one one preferred preferred embodiment, thesolvent embodiment, the solventisis NMP. NMP.

[00020]

[00020] InIn one one embodiment embodiment of the of the present present invention, invention, oneororall, one or more, more, or all, of the of(a), steps the (b), steps(c) (a), (b), (c) and (d) of the first aspect is performed at room temperature, that is, a temperature of from about and (d) of the first aspect is performed at room temperature, that is, a temperature of from about

10 to 35 10 to 35°C; °C;especially especially between between aboutabout 15 to 15 to 30 30 °C, or °C, aboutor20about to 25 20 °C.to 25 °C.

[00021]

[00021] InIn a a second second aspect aspect of present of the the present invention, invention, there there is is provided provided a productaobtained, product or obtained, or obtainable, from obtainable, from thethe method method offirst of the the first aspect. aspect.

[00022]

[00022] InIn a a thirdaspect third aspect of of thethe present present invention, invention, there there is provided is provided an apparatus an apparatus for obtaining for obtaining a a cobalt-enriched material cobalt-enriched material from from aa discharged dischargedlithium lithium ion ion cell cell comprising cobalt, the comprising cobalt, the apparatus apparatus

comprising:aa crushing comprising: crushing device; device; aa sieving sieving device and aa magnetic device and magneticdevice; device;wherein whereinthe thesieving sieving device isadapted device is adaptedto to obtain obtain particles particles of less of less thanthan 4 mm 4inmm in the size, size, the magnetic magnetic device isdevice adaptedis toadapted to

generate a magnetic generate a field of magnetic field of between 2000and between 2000 and8000 8000 Gauss, Gauss, andand thethe apparatus apparatus does does notnot include include a a

heating device. heating device. The terms "crushing The terms “crushingdevice", device”,"sieving “sievingdevice", device”, and and"magnetic “magneticdevice" device” areasas are

described herein. described herein.

Brief Brief Description of Drawings Description of Drawings

[00023] Figure1:1:Determination

[00023] Figure Determinationofof Lithium, Lithium, Cobalt, Cobalt, Nickel Nickel andand Manganese Manganese in Black in Black Powder Powder

by ICP-MS. by ICP-MS.

[00024] Figure2:2:The

[00024] Figure TheGaussian Gaussian intensityofofmagnetic intensity magnetic separation separation from from 1000G 1000G to 5000G. to 5000G.

Definitions Definitions

[00025] The

[00025] The following following definitions definitions are provided are provided tothe to enable enable theperson skilled skilled to person to better understand better understand

the invention disclosed herein. These are intended to be general and are not intended to limit the the invention disclosed herein. These are intended to be general and are not intended to limit the

scope scope ofofthe theinvention inventionto to these these terms terms or definitions or definitions alone.alone. Unless Unless defined defined otherwise, otherwise, all technical all technical 2025259976

and scientific terms and scientific terms used used herein herein have have the the same meaningasascommonly same meaning commonly understood understood by having by one one having ordinary skillininthe ordinary skill theart arttotowhich whichthethe invention invention pertains. pertains.

[00026] Asused

[00026] As usedherein, herein,the the terms terms "recycling" “recycling”and and"recovery" “recovery”oror"resource “resourcerecovery" recovery”(and (and variations thereof) variations thereof)may may be be used interchangeably. As used interchangeably. Asthe the skilled skilled person person would appreciate, would appreciate,

“recycling” commonly "recycling" commonly referstotoa aprocess refers processofofconverting convertingwaste wastematerials materialsinto intonew newmaterials materialsoror objects (suchasasthetherecycling objects (such recycling of waster of waster plastic plastic bottles bottles intobottles into new new bottles orpolymer-based or other other polymer-based objects), whichmaymay objects), which refer refer to ato a portion portion ofwaste of the the waste material material or the entirety or the entirety of the of the waste waste material. material.

As the process of the present invention is directed to the specific recovery of a portion of the As the process of the present invention is directed to the specific recovery of a portion of the

waste cell waste cell or or battery, battery,the term the term“recovery” "recovery"or or“resource "resourcerecovery” recovery" may also apply; may also apply; for for example, example,

the cobalt-enriched the cobalt-enriched materials materials may be"recycled" may be “recycled”following following"recovery" “recovery”ofofthis thismaterial material from fromthe the waste. waste.

[00027]

[00027] AsAs used used herein, herein, the term the term “spent” "spent" (when (when used used in reference in reference to aa battery, to a cell or cell or asuch battery, as such as “a spent battery”) refers to a battery or a cell that has exceeded its useful lifetime, no longer "a spent battery") refers to a battery or a cell that has exceeded its useful lifetime, no longer

maintains a charge sufficient for its intended use, or has degraded sufficiently to require maintains a charge sufficient for its intended use, or has degraded sufficiently to require

disposal, reclamation or recycling. disposal, reclamation or recycling.

[00028] Asused

[00028] As usedherein, herein,the the term term "fragment" “fragment”oror"fragments" “fragments” means means a part a part or or partsbroken parts broken off off

from from a alarger largerthing, thing,ororthethe resulting resulting material material after after a large a large thingthing is broken is broken into smaller into smaller parts. parts. It is It is

also meant that other terms such as “particles”, “pieces”, “portions” and the like fall within the also meant that other terms such as "particles", "pieces", "portions" and the like fall within the

meaningofof"fragments". meaning “fragments”.

[00029] Asused

[00029] As usedherein, herein,the the term term "comprising" “comprising”means means “including”. "including". Variations Variations of of thethe word word

“comprising”,such "comprising", suchasas"comprise" “comprise”and and “comprises”, "comprises", have have correspondingly correspondingly varied varied meanings. meanings. As As used herein, used herein, the the terms terms “including” "including" and “comprising”are and "comprising" arenon-exclusive. non-exclusive.AsAsused usedherein, herein,the the terms "including" terms “including” and and"comprising" “comprising”dodo notimply not imply thatthe that thespecified specifiedinteger(s) integer(s) represent represent aa major major

part of the whole. part of the whole.

[00030] The

[00030] The transitional transitional phrase phrase “consisting "consisting of” excludes of" excludes any step, any element, element, step, or ingredient or ingredient not not specified. If in specified. If in the the claim, claim,such such would would close close the claim the claim to theto the inclusion inclusion of materials of materials other than other than

those recited except for impurities ordinarily associated therewith. When the phrase “consisting those recited except for impurities ordinarily associated therewith. When the phrase "consisting

of” appears in a clause of the body of a claim, rather than immediately following the preamble, of" appears in a clause of the body of a claim, rather than immediately following the preamble,

it it limits limits only the element only the elementsetset forth forth in in that that clause; clause; other other elements elements areexcluded are not not excluded from thefrom claim the claim

as as aa whole. whole. 2025259976

[00031] The

[00031] The transitional transitional phrase phrase “consisting "consisting essentially essentially of" is of” used is toused toadefine define a composition, composition,

process or method that includes materials, steps, features, components, or elements, in addition process or method that includes materials, steps, features, components, or elements, in addition

to those literally disclosed, provided that these additional materials, steps, features, components, to those literally disclosed, provided that these additional materials, steps, features, components,

or elementsdodo or elements notnot materially materially affect affect the basic the basic and characteristic(s) and novel novel characteristic(s) of the claimed of the claimed

invention. invention. The term "consisting The term “consisting essentially essentially of” of" occupies occupies aa middle middle ground between"comprising" ground between "comprising" and “consisting and "consisting of”. of".

[00032] Whereapplicants

[00032] Where applicantshave have defined defined anan invention invention or or a a portionthereof portion thereofwith withananopen-ended open-ended term such as “comprising”, it should be readily understood that (unless otherwise stated) the term such as "comprising", it should be readily understood that (unless otherwise stated) the

description should description should be be interpreted interpreted to also to also describe describe such such an an invention invention using theusing terms the terms “consisting "consisting

essentially of”oror"consisting essentially of" “consistingof.of. In ”other In other words,words, with respect with respect to the to the terms terms “comprising”, "comprising",

“consisting of”, and “consisting essentially of”, where one of these three terms are used herein, "consisting of", and "consisting essentially of", where one of these three terms are used herein,

the presently disclosed and claimed subject matter may include the use of either of the other two the presently disclosed and claimed subject matter may include the use of either of the other two

terms. Thus, terms. in some Thus, in embodiments some embodiments notnot otherwise otherwise explicitlyrecited, explicitly recited,any anyinstance instanceofof “comprising” "comprising" may may be replaced be replaced by “consisting by "consisting of” or, alternatively, of" or, alternatively, by “consisting by "consisting essentially essentially

of”. of".

[00033] Further,

[00033] Further, unless unless expressly expressly stated stated to thetocontrary, the contrary, “or” to "or" refers refers to an inclusive an inclusive ortoand not to or and not

an exclusiveor.or.ForFor an exclusive example, example, a condition a condition A or BAisor B is satisfied satisfied by any by any one one of the of the following: following: A is A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or true (or present) and B is false (or not present), A is false (or not present) and B is true (or

present), and both A and B are true (or present). present), and both A and B are true (or present).

[00034] Also, the

[00034] Also, the indefinite indefinite articles articles“a” "a"and and“an” "an"preceding preceding an an element element or or component ofthe component of the invention areintended invention are intended to non-restrictive to be be non-restrictive regarding regarding the number the number of instances of instances (i.e., occurrences) (i.e., occurrences)

of the of the element element or or component. Therefore"a" component. Therefore “a”oror"an" “an”should shouldbeberead readtotoinclude includeone oneororatat least least one, one, and the singular and the singular word formof word form of the the element elementor or component component alsoincludes also includesthe theplural pluralunless unlessthe the numberisisobviously number obviouslymeant meanttotobebesingular. singular.

[00035] Theterms

[00035] The terms"predominantly" “predominantly”andand “substantially” "substantially" as as used used herein herein shallmean shall mean comprising comprising

morethan more than50% 50%byby weight, weight, unless unless otherwise otherwise indicated. indicated.

[00036] Otherthan

[00036] Other thaninin the the operating operating examples, examples,oror where whereotherwise otherwiseindicated, indicated,all all numbers numbers expressing quantities expressing quantities of of ingredients ingredients or reaction or reaction conditions conditions usedare used herein herein to beare to be understood understood as as modifiedin modified in all all instances instances by by the theterm term “about”. "about". As As used used herein, herein, the theterms terms “about” "about" and and

“approximately” areunderstood understoodtotorefer referto to the the range range of of -10% to +10% +10% ofof thereferenced referencednumber, number, 2025259976

"approximately" are -10% to the

preferably -5% preferably to +5% -5% to +5%ofofthe thereferenced referencednumber, number, more more preferably preferably -1%-1 to%+ to 1 + % 1 of%the of the referenced number, referenced number,most mostpreferably preferably-0.1 -0.1% %toto+0.1 +0.1% % of of thereferenced the referencednumber. number. Moreover, Moreover, withwith

reference to reference to numerical ranges, these numerical ranges, these terms terms should be construed should be construed as as providing providing support supportfor for aa claim claim

directed to directed to any any number or subset number or subset of of numbers numbersininthat that range. range. For For example, example,aadisclosure disclosure of of from from 11 to 10 should be construed as supporting a range of from 1 to 8, from 3 to 7, from 1 to 9, from to 10 should be construed as supporting a range of from 1 to 8, from 3 to 7, from 1 to 9, from

3.6 to 4.6, 3.6 to 4.6, from from3.5 3.5toto9.9, 9.9,from from 8 10, 8 to to 10, and and so forth. so forth.

Abbreviations Abbreviations

[00037] The

[00037] The following following abbreviations abbreviations areherein are used usedinherein in relation relation to batterytochemistries: battery chemistries:

LCO:Lithium LCO: Lithium Cobalt Cobalt oxide oxide

LNO:Lithium LNO: Lithium Nickel Nickel oxide oxide

NCA:Lithium NCA: LithiumNickel Nickel Cobalt Cobalt Aluminium oxide Aluminium oxide

NMC:Lithium NMC: LithiumNickel Nickel Manganese ManganeseCobalt Cobaltoxide oxide

LMO:Lithium LMO: LithiumManganese Manganeseoxide oxide

LFP:Lithium LFP: LithiumIron IronPhosphate Phosphate

LTO:Lithium LTO: Lithium Titanate Titanate

[00038] Thefollowing

[00038] The followingabbreviations abbreviationsare arealso alsoused usedherein: herein:

ICP-MS:Inductively ICP-MS: InductivelyCoupled Coupled Plasma Plasma MassMass Spectroscopy Spectroscopy

9 31 Oct 2025

PVDF:Polyvinylidene PVDF: Polyvinylidene fluoride fluoride

DMF:dimethyl DMF: dimethyl formamide formamide

DMSO:dimethyl DMSO: dimethylsulfoxide sulfoxide

NMP:N-methyl-2-pyrrolidone NMP: N-methyl-2-pyrrolidone 2025259976

DMAc: dimethylacetamide DMAc: dimethylacetamide

Description Description of ofEmbodiments Embodiments

[00039] Thefollowing

[00039] The followingdescription descriptionconveys conveys exemplary exemplary embodiments embodiments of theofpresent the present invention invention in in sufficient detail to sufficient detail to enable enablethose those of of ordinary ordinary skill skill in the in the art art to practice to practice the present the present invention. invention.

Features or Features or limitations limitations of ofthe thevarious variousembodiments describeddodonot embodiments described notnecessarily necessarily limit limit other other

embodiments embodiments of of thepresent the presentinvention inventionororthe thepresent presentinvention inventionas as aa whole. whole. Hence, Hence,the thefollowing following detailed description does not limit the scope of the present invention, which is defined only by detailed description does not limit the scope of the present invention, which is defined only by

the claims. the claims.

[00040] The

[00040] The present present invention invention relates relates to a method to a method for processing for processing usedtobatteries used batteries recover to recover

valuable metals, especially cobalt. valuable metals, especially cobalt.

[00041] In particular,

[00041] In particular, the theinventor inventorhas hasdeveloped developed aa method for processing method for cobalt-containing processing cobalt-containing

batteries which allows for the efficient recovery of cobalt, whereby other metals (such as iron, batteries which allows for the efficient recovery of cobalt, whereby other metals (such as iron,

aluminium andcopper) aluminium and copper) areseparated are separatedfrom from thecobalt. the cobalt.AsAswill willbebedescribed describedininmore moredetail detailbelow below and with and with reference reference to to the the Examples, the method Examples, the methodofofsome some aspectsofofthe aspects thepresent presentinvention inventionhas has been developed to be an efficient process that utilises relatively low-cost components that are been developed to be an efficient process that utilises relatively low-cost components that are

efficient totooperate. efficient operate.InInsome someaspects aspectsthe themethod method of of the thepresent presentinvention inventionadvantageously advantageously avoids avoids

the use the use of of aa heat heattreatment treatmentstep stepthat is is that common common in in known processes, but known processes, but which whichisis energy- energy- intensive intensive and and increases increases the the costs costsof ofcarrying carryingout outsuch suchrecovery recoveryprocesses. processes. Although the present Although the present invention hasbeen invention has been developed developed with with the the intention intention of recycling of recycling lithium lithium ion ion batteries, batteries, it is it is anticipated by the inventor that this process may be suitable for recovering cobalt from batteries anticipated by the inventor that this process may be suitable for recovering cobalt from batteries

and cells based on alternative chemistries. and cells based on alternative chemistries.

10 31 Oct 2025

Batteries Batteries

[00042]

[00042] AsAs thethe skilled skilled person person wouldwould appreciate, appreciate, current current batteriesbatteries are basedare on based a range on of a range of anodic anodic

and cathodic and cathodic chemistries. chemistries. For For instance, instance, although although “lithium "lithium ion” batteries ion" batteries allmobile all utilise utiliselithium mobile lithium ions, ions, the thechemistry chemistry of of the theanode anode and and cathode can vary, cathode can vary, which hasan which has aneffect effect on the power on the output, power output,

safety, safety, lifetime lifetimeand andcost costofofa battery. Table a battery. 1 below Table summarises 1 below summarises the the various various anode anode and and cathode cathode

materials found in lithium ion batteries, whereby the relative power, safety and lifetime are 2025259976

materials found in lithium ion batteries, whereby the relative power, safety and lifetime are

provided by the scale: -- < - < O < + < ++ < +++. provided by the scale:

Table 1: Comparison Table 1: Comparison of of lithiumion lithium ionbattery batterycomponents. components.

Name Name LCO LNO NCA NMC LMO LFP LFP LTO LTO LCO LNO NCA NMC LMO e.g., e.g., Li(Ni 0.85Co Li(Ni.85Co Li(Ni0.33Mn0.33 Li(Nio.33Mno.33 Cathode Cathode LiCoO2 LiCoO LiNiO2 LiNiO LiMn2O4 LiFePO4 LiFePO LMO, LMO, O0.1Al0.05)O2 Co0.33)O2 LiMnO O.Al.)O Co.)O NCA NCA Anode Anode Graphite Graphite Graphite Graphite Graphite Graphite Graphite Graphite Graphite Graphite Graphite Graphite Li4Ti5O12 LiTiO Cell Cell 3.7-3.9V 3.7-3.9V 3.6V 3.6V 3.65V 3.65V 3.8-4.0V 3.8-4.0V 4.0V 4.0V 3.3V 3.3V 2.3-2.5V 2.3-2.5V voltage voltage

Energy Energy 150 150 150 150 120 120 130 130 85 85 130 130 mAh/g mAh/g 170 170 mAh/g mAh/g Density Density mAh/g mAh/g mAh/g mAh/g mAh/g mAh/g mAh/g mAh/g mAh/g mAh/g Power Power + + O O + + O O + + + + ++ ++ Safety Safety -- O O O O O O + + ++ ++ ++ ++ Lifetime Lifetime -- O O + + O O O O + + +++ +++ Cost Cost -- -- + + O O O O + + + + O O

[00043] Aswill

[00043] As will be be described describedin in more moredetail detail below, below, in in some someembodiments embodimentsthe the method method of the of the

present invention present invention is is particularly particularlysuitable forfor suitable recovering cobalt recovering from cobalt batteries from with batteries LCO, with LCO,NCA, NCA,

NMC NMC andand suitable suitable LTO LTO lithium lithium ion ion batteries. batteries.

Recovery Method Recovery Method

[00044]

[00044] AtAt present, present, typical typical recycling recycling processes processes for lithium for waste waste lithium ion batteries ion batteries generally generally include include the steps the steps of ofaadischarge dischargetreatment treatmentand and then then physical physical processing processing to toobtain obtainthe theanode anode and and cathode cathode

materials materials (known inthe (known in the art art as as “black "black powder”). This black powder"). This black powder powderisisusually usually then then processed processedvia via heat treatment heat treatment (pyrometallurgy) to obtain (pyrometallurgy) to obtain the the valuable valuable metals metals in in the the black black powder, powder, before before the the

11 31 Oct 2025

remainingmaterials remaining materialsare are disposed disposedof. of. Without wishingtotobebebound Without wishing boundbybytheory, theory,the theinventor inventorhas has found thatthe found that theuse useofof magnetic magnetic separation separation on particles on particles of a certain of a certain size effectively size effectively separate separate the the elements of the elements of the black black powder withoutthe powder without theneed needfor foraapyrometallurgical pyrometallurgicalprocess. process.

[00045] In one

[00045] In one embodiment embodiment of of thethe presentinvention, present invention,there thereisis provided providedaamethod methodforforobtaining obtaininga a cobalt-enriched material, comprising: cobalt-enriched material, comprising:

(a) (a) providing providing a a discharged lithium ion comprising cell comprising cobalt; cobalt; 2025259976

discharged lithium ion cell

(b) crushingthe (b) crushing thecell celltotoform form fragments; fragments;

(c) (c) separating thefragments separating the fragments to obtain to obtain (or provide) (or provide) particles particles of lessofthan less4mm than in 4mm in size; and size; and

(d) (d) treating theobtained treating the obtained(or(or provided) provided) particles particles with with a magnetic a magnetic field offield of between between 2000 2000 and 8000Gauss, and 8000 Gauss,sosoasasto to select select cobalt-enriched cobalt-enriched material material from non-cobalt-enrichedmaterial, from non-cobalt-enriched material, whereinthe wherein the method methoddoes doesnot notcomprise comprise a heattreatment. a heat treatment.

[00046] Thelithium

[00046] The lithiumion ioncell cell may befound may be foundwithin withina abattery, battery, or or it itmay may be be another another

electrochemical cell electrochemical cell (e.g.,anan (e.g., electrolysis electrolysis cellcell or aorgalvanic a galvanic cell,cell, for instance). for instance). The lithium The lithium ion ion cell cell comprises comprises cobalt cobalt (for (for example, example, it itmay may be be aa battery batterywith with LCO, NCA,NMCNMC LCO, NCA, or suitable or suitable LTO LTO

chemistry). Preferably, the lithium ion cell comprises cobalt in either the anode material, the chemistry). Preferably, the lithium ion cell comprises cobalt in either the anode material, the

cathode material, cathode material, or or both. both.

[00047] The

[00047] The lithium lithium ion ion cell cell is discharged is discharged beforebefore processing processing in this As in this method. method. As the skilled the skilled

person will person will appreciate, appreciate, batteries batteriesare commonly are dischargedbefore commonly discharged beforemechanical mechanical processing,toto processing,

reduce the risks of fire and explosions that can occur, given the high voltages and reactive reduce the risks of fire and explosions that can occur, given the high voltages and reactive

components commonly components commonly found found in spent in spent lithium lithium ion ion batteries. batteries. Discharging Discharging can can reduce reduce thisthis risk risk by by

reducing the reducing the electrochemical electrochemical potential potential of of the the cell cellororbattery. battery.InIn some someembodiments, the cell embodiments, the cell may may

be fully, substantially or partially discharged, provided it is sufficiently discharged for be fully, substantially or partially discharged, provided it is sufficiently discharged for

processing. processing.

[00048] Thedischarged

[00048] The dischargedlithium lithiumion ioncell cell is is then then crushed to produce crushed to fragments. Any produce fragments. Anysuitable suitable mechanical process can be used to crush the cell, so long as the outer casing (if any) is ruptured mechanical process can be used to crush the cell, so long as the outer casing (if any) is ruptured

and the contents of the interior (including, for example, the electrolyte, the anode material, the and the contents of the interior (including, for example, the electrolyte, the anode material, the

cathode material, cathode material, wiring, wiring, supporting supporting structures structures and control and control structures) structures) are exposed. are exposed. The The fragments obtained fragments obtained fromfrom the crushing the crushing step step may may comprise comprise any solid any solid features of features ofbattery, the cell or the cell or battery, such asthe such as theanode anode material, material, cathode cathode material, material, casingcasing andinternal and other other internal components. components. In a In a preferred embodiment, preferred theanode embodiment, the anodeandand cathode cathode materials materials areare rendered rendered to to form form particlesininthis particles this

12 31 Oct 2025

step (that is, step (that is, the the fragments comprise fragments comprise particles particles of anode of the the anode and/or and/or cathode cathode materials). materials). As the As the skilled personwould skilled person would appreciate, appreciate, it isitthe is the cathode cathode and/orand/or the material the anode anode material (depending(depending on the on the specific chemistry specific chemistry employed employed by theby the battery) battery) that contains that contains the majority the majority of the recoverable of the recoverable

valuable metals, such as cobalt. It is therefore preferred that the electrode material is reduced in valuable metals, such as cobalt. It is therefore preferred that the electrode material is reduced in

size to form size to formparticles particlesininthethecrushing crushing step. step. In other In other embodiments, embodiments, a further a further processing processing step is step is required after crushing the discharged cell or battery in order to form particles from the required after crushing the discharged cell or battery in order to form particles from the 2025259976

electrode materials. electrode materials.

[00049] After

[00049] After thethe crushing crushing step,step, the method the method of the of the present present invention invention requires arequires step of a step of

separating separating the the fragments obtained from fragments obtained fromthe thecrushing crushingstep. step. The Theinventors inventors have havesurprisingly surprisingly found found that particles of a certain size are particularly suitable for obtaining an enriched cobalt product that particles of a certain size are particularly suitable for obtaining an enriched cobalt product

from from a aused usedlithium lithium ion ion cellcell or battery. or battery. Particularly Particularly suitable suitable sizes sizes forparticles for the the particles arethan are less less than about about 44 mm, mm,ororless less then then about about 33 mm, mm,ororless less than than about about22 mm, mm,ororless lessthan thanabout about1.5 1.5 mm, mm,oror less less than than about about 11 mm, or any mm, or any range rangetherein, therein, such such as as between about3030µmμmandand between about about about 4 mm, 4 mm, or or

betweenabout between about4545µmμm andand 3 mm, 3 mm, or between or between about about 63 µm63and μmabout and about 1.2ormm, 1.2 mm, or between between about about 100 μmand 100 µm andabout about2.5 2.5mm, mm,or or between between about about 250 250 μm 1and µm and mm,1for mm,example. for example.

[00050] Anysuitable

[00050] Any suitableseparation separationmethod methodmaymay be be suitable suitable forfor obtaining(or(orproviding) obtaining providing)particles particlesof of aa particular sizerange particular size rangeasasdescribed described herein. herein. The inventors The inventors havethat have found found that a efficient a suitably suitably efficient and and low-cost option low-cost option is is to to use use oneone or more or more sieves sieves of particular of particular sizesallow sizes which whichforallow for the rejection the rejection of of particles that all outside the range of the particles desired by the user. For example, a sieve with particles that all outside the range of the particles desired by the user. For example, a sieve with

aa 44 mm aperturemay mm aperture maybebeused used toto remove remove larger larger particlesand particles andother othermaterials, materials,whereby whereby the the

material that passes through the 4 mm sieve is collected. If a particular particle size range is material that passes through the 4 mm sieve is collected. If a particular particle size range is

desired, thesesieved desired, these sieved particles particles maymay then then be sorted be sorted using using a fine a finesieve, mesh meshwhereby sieve,the whereby materialthe material

that is retained by the sieve is collected. It is anticipated that the skilled can optimise this that is retained by the sieve is collected. It is anticipated that the skilled can optimise this

separation process separation process in in order order to obtain to obtain the particles the particles that that are desired are desired for further for further processing. processing.

[00051] The

[00051] The particles particles of aofparticular a particular sizesize that that are obtained are obtained following following separation separation from the waste from the waste

materials are materials are then then exposed to aa magnetic exposed to field. The magnetic field. The magnetic field may magnetic field be between may be betweenabout about2000 2000 Gauss andabout Gauss and about8000 8000Gauss, Gauss, such such as as between between about about 3000 3000 and and 50005000 Gauss, Gauss, or between or between about about

2500Gauss 2500 Gaussand and7500 7500 Gauss, Gauss, or or between between about about 40004000 and 6000 and 6000 Gauss, Gauss, or anyorrange any range therein. therein. The The magneticfield magnetic field may beprovided may be providedbybyany anysuitable suitabledevice. device.InInone oneembodiment, embodiment,thethe magnetic magnetic field field

is is provided provided by by a a magnetic separator so magnetic separator so as as to to separate separate ferromagnetic ferromagnetic and strongly paramagnetic and strongly paramagnetic

particles from particles from particles particlesthat thatareareweakly weaklyparamagnetic paramagnetic or or non-metallic. non-metallic. The The magnetic separator magnetic separator

13 31 Oct 2025

maybebeany may anysuitable suitable conventional conventionalapparatus, apparatus,such suchasasfor for example, example,a apermanent permanent magnetic magnetic drum drum

separator ora across-belt separator or cross-beltseparator. separator. Such Such conventional conventional apparatus apparatus for the separation for the separation of of ferromagnetic andstrongly ferromagnetic and stronglyparamagnetic paramagneticparticles particleswould wouldbebewell-known well-known to the to the skilledperson. skilled person.

[00052] Themagnetic

[00052] The magneticfield fieldmay may optionallyalso, optionally also,ororinstead, instead, be be provided providedby byan aneddy eddycurrent current separator. separator. As As the the skilled skilledperson personwould would be be aware, eddycurrent aware, eddy current separation separation processes processes utilise utilise eddy eddy

currents currents to to separate separateparticles. This technique is is commonly commonly used used to to separate separate non-ferrous non-ferrous metals 2025259976

particles. This technique metals

from non-metals,whereby from non-metals, whereby theparticles the particlesare are passed passedalong alongaaconveyor conveyorbelt belttotoan aneddy eddycurrent current rotor, resulting in the non-ferrous metal particles being caught in an eddy current and caught in a rotor, resulting in the non-ferrous metal particles being caught in an eddy current and caught in a

product bin, while the non-metal particles that do not interact with the eddy current fall off the product bin, while the non-metal particles that do not interact with the eddy current fall off the

belt. In one particular embodiment, the eddy current separator is used after a magnetic separator, belt. In one particular embodiment, the eddy current separator is used after a magnetic separator,

as the presence as the presenceofofferrous ferrous particles particles in eddy in an an eddy current current separator separator can the can damage damage the (since separator separator (since ferrous ferrous materials materials heat heat up up when exposedtotoananeddy when exposed eddycurrent). current).

[00053] Step(d)

[00053] Step (d) of of the the method of the method of the present present invention invention may optionallyfurther may optionally further comprise compriseuse useofof an electrostaticseparator. an electrostatic separator.As As the the skilled skilled person person would would appreciate, appreciate, an electrostatic an electrostatic separator separator may may also beused also be usedtotoseparate separate particles particles based based on differing on differing electrostatic electrostatic charges. charges. Such electrostatic Such electrostatic

separators separators would beknown would be knowntoto theskilled the skilled person. person.

[00054] Eachofofthe

[00054] Each the abovementioned abovementioned magnetic, magnetic, eddy eddy current current and and electrostatic electrostatic separators separators may, may, in in

some embodiments, some embodiments, employ employ a rotating a rotating drum, drum, whereby whereby a permanent a permanent magnetmagnet or electromagnet or electromagnet are are employed inside employed inside the the drum, drum, and particles and particles that that are are attracted attracted to the magnetic to the magnetic field are field are attracted attracted to to the surface of the drum and hence separated from particles that are not attracted to the magnetic the surface of the drum and hence separated from particles that are not attracted to the magnetic

field, field, or or particles withananelectrostatic particles with electrostaticcharge charge are are attracted attracted to the to the drumdrum and conditions, and other other conditions, such asananionizing such as ionizing discharge, discharge, disrupt disrupt the electrostatic the electrostatic attraction attraction to theto theofdrum drum of aofsubset a subset those of those

particles. InInsuch particles. suchapparatus, apparatus,the thedrum drum may be no may be morethan no more thanabout about3030cmcmininlength, length,which whichthe the inventor inventor has has found to be found to be useful useful in in the thepresent presentinvention. invention.In Insome some embodiments, therotating embodiments, the rotating drum drum ofof a a magnetic magnetic separator, separator, and/or and/or ancurrent an eddy eddy current separator, separator, and/or an and/or an electrostatic electrostatic separator separator

maybebebetween may betweenabout about 1515 andand 30 30 cm,cm, or or between between about about 20 and 20 and 25 or 25 cm, cm,between or between about about 10 and10 and 20 cm, 20 cm, or or between betweenabout about2525and and3030cm.cm.

[00055] Themethod

[00055] The methodof of thepresent the presentinvention inventionmay may include include an an optional optional additionalprocessing additional processing step step

of exposing the particles obtained from the crushing step to a solvent. As the skilled person of exposing the particles obtained from the crushing step to a solvent. As the skilled person

would appreciate, electrodes that are used in lithium ion cells and batteries generally comprise: would appreciate, electrodes that are used in lithium ion cells and batteries generally comprise:

14 31 Oct 2025

(1) (1) an aluminium an aluminium substrate substrate (e.g., (e.g., aluminium aluminium foil); foil); (2) the(2) the active active materialmaterial (e.g., (e.g., the the lithium- lithium-

containing material); (3) a conductive additive (added to increase conductivity); and (4) a containing material); (3) a conductive additive (added to increase conductivity); and (4) a

binder. The binder. binder may The binder maybebea apolymer. polymer.The The polymer polymer binder, binder, when when used, used, mustmust be abe a robust robust

polymer,as polymer, as it it may be in may be in contact contact with with the the electrolyte electrolyte(which (which frequently frequently comprises comprises a a combustible combustible

solvent) and solvent) and may beexposed may be exposedtotomany many heating heating andand cooling cooling cycles cycles (as(as heat heat isisgenerated generatedduring during recharging and recharging anddischarging dischargingofofaa battery battery or or use use of of aacell). cell).AnAnexample example of of aacommon polymer common polymer 2025259976

binder is PVDF, which is a robust polymer that is resistant to a range of solvents, acids and binder is PVDF, which is a robust polymer that is resistant to a range of solvents, acids and

hydrocarbons.However, hydrocarbons. However, PVDF PVDF can can be be dissolved dissolved or degraded or degraded bysolvents. by some some solvents. Any solvent Any solvent

that is suitable for dissolving or degrading PVDF may be suitable for use in this optional step. that is suitable for dissolving or degrading PVDF may be suitable for use in this optional step.

Examples Examples ofofsuitable suitablesolvents solvents include include DMF, DMF, DMSO, DMSO, NMP NMP or or One DMAc. DMAc. One particularly particularly suitable suitable

solvent solvent is is NMP. NMP.

[00056] In one

[00056] In one embodiment, embodiment, thethe resultofofthe result the method methoddescribed describedherein hereinisisthe theselective selective enrichment enrichment of of particles particles that that comprise comprise cobalt. cobalt. Put differently, Put differently, impurities impurities present present inion in lithium lithium ion cells cells and batteriessuch and batteries suchas,as,forforexample, example, iron, iron, aluminium, aluminium, copper,copper, lithium lithium and and graphite, graphite, are are removedfrom removed fromthetheobtained obtainedproduct product byby use use of of thepresent the presentmethod, method, thereby thereby resultingininthe resulting the relative enrichment of cobalt in the particles that are obtained. relative enrichment of cobalt in the particles that are obtained.

[00057] Surprisingly, the

[00057] Surprisingly, the method developedbyby method developed theinventor the inventordoes doesnotnotrequire requirea aheating heatingstep. step. Industrial recycling Industrial recycling and and recovery recovery processes processes for for metallic metallic elements elements commonly utiliseaa heating commonly utilise heating step, usuallyunder step, usually under reducing reducing conditions, conditions, to convert to convert metallic metallic ions ions into intoelemental their their elemental form. form. However, However, thethe inventor inventor has shown has shown thata step that such suchisa step is not necessary not necessary inrecover in order to order to recover a cobalt- a cobalt-

enriched portion enriched portion of of thethe lithium lithium ion ion cell cell or battery or battery that that is processed. is processed. Without Without wishing wishing to to be bound be bound

to theory, it is expected that this is due to the particular separation steps that are employed, to theory, it is expected that this is due to the particular separation steps that are employed,

wherebysome whereby some impurities impurities areremoved are removed through through sizesize exclusion exclusion (for (for example, example, large large portions portions of of thethe

casing casing and internal components, and internal suchasasaluminium components, such aluminium foilused foil usedininthe thecathode cathodeororcopper copperwiring wiring used to complete the circuit) and other impurities are removed based on their interaction (or lack used to complete the circuit) and other impurities are removed based on their interaction (or lack

thereof) with a magnetic field and/or eddy current and/or electrostatic charge (such as the thereof) with a magnetic field and/or eddy current and/or electrostatic charge (such as the

graphite graphite of of the the anode, anode, which is non-magnetic). which is non-magnetic).

[00058] Accordingly,asasthe

[00058] Accordingly, theonly onlyprocesses processesrequired requiredbybythe themethod methodofofthe thepresent presentinvention invention including crushing, sieving, including crushing, sieving, and and magnetic separation (which magnetic separation (whichcan canbebeapplied appliedbybyusing usingpermanent permanent magnets), the magnets), the energy energy consumption consumptionof of themethod the methodmaymay be relatively be relatively low. low. In In other other words, words, by by

developing a process that does not require a heating step (which is energy intensive) and can developing a process that does not require a heating step (which is energy intensive) and can

15 31 Oct 2025

avoid the use avoid the use of of aa strong strong electromagnet electromagnet (in (in some embodiments),thetheinventor some embodiments), inventorhas has advantageously developed advantageously developed a processwith a process with relativelylow relatively lowenergy energyconsumption. consumption. Further, Further, thethe

processes of processes of the the present present method utilise equipment method utilise that are equipment that are commonly obtained commonly obtained and and also also

relatively simple to operate, thereby meaning that the costs of installation, operation and relatively simple to operate, thereby meaning that the costs of installation, operation and

maintenance are also relatively low, leading to a commercially beneficial process. maintenance are also relatively low, leading to a commercially beneficial process.

Recovery Apparatus Apparatus 2025259976

Recovery

[00059] Themethod

[00059] The methodof of thepresent the presentinvention inventionasasdescribed describedabove above can can be be carriedout carried outononseparate separate devices, or it can be carried out on a single apparatus. devices, or it can be carried out on a single apparatus.

[00060] Accordingly,ininone

[00060] Accordingly, oneembodiment embodiment of the of the present present invention, invention, thereisisprovided there providedanan apparatus for obtaining apparatus for obtaining a a cobalt-enriched cobalt-enriched material material from a discharged from a lithium ion discharged lithium ion cell cell comprising comprising

cobalt, cobalt, the theapparatus apparatus comprising: comprising: a a crushing crushing device; device; aa sieving sieving device device and and aa magnetic device; magnetic device;

wherein the sieving device is adapted to obtain particles of less than 4 mm in size, the magnetic wherein the sieving device is adapted to obtain particles of less than 4 mm in size, the magnetic

device is adapted device is adapted to to generate generate aa magnetic magnetic field field of ofbetween between 2000 and8000 2000 and 8000Gauss, Gauss,andand the the

apparatus does apparatus does notnot include include a heating a heating device. device.

[00061] Thecrushing

[00061] The crushingdevice devicemay maybe be anyany suitable suitable device device forcrushing for crushing a a spentlithium spent lithiumion ioncell cell or or battery. It may include rollers, shredders, impact crushers, hammer mills and the like. battery. It may include rollers, shredders, impact crushers, hammer mills and the like.

[00062] Thesieving

[00062] The sievingdevice devicemay may comprise comprise oneone or or more more sieves. sieves. TheThe sieve(s) sieve(s) generally generally comprise comprise a a

meshwith mesh withdefined definedand anduniform uniform aperturesthat apertures thatcan canbebeused usedtotosort sort fragments fragmentsinto intodifferently differently sized fractions.The sized fractions. Thesieve(s) sieve(s) cancan be selected be selected byskilled by the the skilled personperson depending depending on the particle on the particle

fraction that is fraction that is desired. desired.Where Wheremoremore than than one is one sieve sieve is utilised, utilised, they they can be can used be used inthat in series, series, is, that is,

aa fraction obtainedfrom fraction obtained from a first a first sieve sieve (either (either the the retained retained fraction fraction orfraction or the the fraction that passed that passed

through the sieve) can then be treated with a sieve with a different aperture, in order to obtain through the sieve) can then be treated with a sieve with a different aperture, in order to obtain

particles of a desired size range. particles of a desired size range.

[00063] Themagnetic

[00063] The magneticdevice device may may be be anyany suitable suitable device device forfor generating generating thethe required required magnetic magnetic

field field (that (thatis,is, between betweenabout about2000 2000and and 8000 8000 Gauss) andseparating Gauss) and separatingmagnetic magneticparticles particles from fromnon- non- magneticparticles. magnetic particles. The device may The device maycomprise comprisea a strongpermanent strong permanent magnet magnet (such (such as, as, forfor example, example,

aa neodymium-based rare neodymium-based rare earth earth magnet) magnet) or or an an electromagnet. electromagnet. TheThe magnetic magnetic device device may also may also

comprise comprise aa barrier barrier between the particles between the particles and and the the magnet (to avoid magnet (to avoid the the magnetic particles from magnetic particles from

16 31 Oct 2025

adhering directly to the magnet), especially if a permanent magnet is being used. The barrier adhering directly to the magnet), especially if a permanent magnet is being used. The barrier

may be in the form of a rotating drum or a plate, for example. may be in the form of a rotating drum or a plate, for example.

[00064] Theapparatus

[00064] The apparatusadvantageously advantageously does does notnot include include a heating a heating device. device. By By “not "not include include a a

heating device”, it is meant that the apparatus does not include a device that has the sole, or heating device", it is meant that the apparatus does not include a device that has the sole, or

main, purpose main, purposeofof raising raising the the temperature of aa material. temperature of material. In Inother otherwords, words,whilst whilstsome some elements of elements of

the apparatus may result in a temperature gain by a part of the battery or cell being processed 2025259976

the apparatus may result in a temperature gain by a part of the battery or cell being processed

(for (for example, the example, the battery battery or or cell cell fragments fragments immediately immediately after crushing after crushing are likelyare to likely have a to have a higher higher

temperature than the whole cell or battery before crushing), an increase in temperature is not the temperature than the whole cell or battery before crushing), an increase in temperature is not the

sole sole purpose or main purpose or aimofofthese main aim these elements. elements. Put Putdifferently, differently, the the apparatus apparatus does doesnot not include include aa device for the sole purpose of heating any portion of the cell or battery being processed. This is device for the sole purpose of heating any portion of the cell or battery being processed. This is

an important an important aspect, aspect, as as thethe ability ability to obtain to obtain a cobalt-rich a cobalt-rich product product withoutwithout a heating a heating step provides step provides

the present the present invention invention with with commercial advantagesover commercial advantages over otherrecycling other recyclingororrecovery recoveryprocesses, processes, leading toananapparatus leading to apparatus with with low low relatively relatively energyenergy costs costs and and hence hence low low costs. operating operating costs.

[00065] Thepresent

[00065] The presentinvention inventionwill will be be further further described belowwith described below withreference referencetoto non-limiting non-limiting worked examples. worked examples.

Examples Examples

[00066]

[00066] AAnon-limiting non-limitingexample exampleof of thepresent the presentinvention inventionisisdescribed describedbelow. below.

[00067]

[00067] AAspent spentlithium lithiumion ionbattery battery with with NMC NMC chemistry chemistry waswas obtained obtained and and discharged discharged by by

immersion immersion ininaaconductive conductiveelectrolyte electrolyte solution. solution. The Thedischarged dischargedbattery batterywas wasthen thencrushed crushedininanan industrial shredding industrial shredding device device and and the solid the solid fragment fragment collected, collected, with thewith theelectrolyte liquid liquid electrolyte discarded. discarded.

[00068] Largecomponents

[00068] Large componentsareare removed removed by hand, by hand, leaving leaving behind behind the black the black mass mass powder, powder, beforebefore

sieves withdifferent sieves with differentmesh mesh sizes sizes werewere thentoused then used to classify classify themass the black black mass particles. particles. To To determine the determine the best best particle particle sizes, sizes, three three different different sieves sieves were were used, used, and theand the content cobalt cobalt of content the of the resulting retained resulting retained fraction fractionanalysed analysed(as (asshown shown in in Table Table 22 below and Figure below and Figure1). 1). The Themesh meshsizes sizes used were used were10 10mesh mesh(2000 (2000 microns), microns), 16 16 mesh mesh (1190 (1190 microns) microns) and mesh and 230 230 mesh (63 microns). (63 microns).

17 31 Oct 2025

Table2:2: Cobalt Table Cobaltcontent contentof of black black mass masscorresponding correspondingtoto differentsieves. different sieves.

Co content (%) Co content (%)

Original Original black black mass mass 13 13

Sieve 1 (10 Sieve 1 (10 mesh) mesh) 18.6 18.6

Sieve 2 (16 (16 mesh) 21.38 2025259976

Sieve 2 mesh) 21.38

Sieve 3 (230 Sieve 3 (230 mesh) mesh) 23.77 23.77

[00069] Ascan

[00069] As canbebeseen seenfrom fromTable Table 2 2 and and Figure Figure 1, 1, thethe particlesthat particles that are are obtained obtained from fromthe the sieving stepinclude sieving step includean an enrichment enrichment of cobalt. of cobalt.

[00070] This

[00070] This enrichment enrichment is further is further increased increased by exposing by exposing these particles these particles to afield. to a magnetic magnetic In field. In particular, a rotating drum separator with a 30 cm diameter was used at a range of magnetic field particular, a rotating drum separator with a 30 cm diameter was used at a range of magnetic field

strengths. strengths. As As shown in Table shown in Table33below, below,atat relatively relatively low low magnetic fields (1000 magnetic fields Gauss), only (1000 Gauss), only 3% 3% of the of the black black powder wasretained powder was retainedby bythe thedrum, drum,increasing increasingtoto85% 85%atat5000 5000Gauss. Gauss. These These results results

are are shown in Figure shown in Figure2.2.

Table3:3: The Table Theblack blackmass massseparation separationrate ratecorresponding correspondingtotothe theGaussian Gaussianintensity intensityofofmagnetic magnetic separation. separation.

Gaussian intensity Gaussian intensity Separation rate(%) Separation rate(%)

1000 1000 G G 33

2000 GG 2000 10 10

3000 3000 G G 45 45

5000 5000 G G 85 85

[00071] Accordingly,

[00071] Accordingly, as be as can can be seen, seen, at relatively at relatively high magnetic high magnetic fields, a fields, greater aproportion greater proportion of of material is separated from the black mass particles. Without being bound to theory, it is material is separated from the black mass particles. Without being bound to theory, it is

expected that the expected that the material material retained retainedon on the thedrum drum is is ferromagnetic ferromagnetic and and paramagnetic material, paramagnetic material,

wherebythe whereby thehigher higherthe themagnetic magneticfield, field, the the greater greater the the amount of paramagnetic amount of paramagneticmaterial materialisis

18 31 Oct 2025

retained. Therefore, the combination of sieving followed by magnetic separation results in the retained. Therefore, the combination of sieving followed by magnetic separation results in the

collection ofaaproduct collection of product that that is is enriched enriched in cobalt. in cobalt.

[00072] Althoughthe

[00072] Although theinvention inventionhas hasbeen beendescribed describedwith with referencetotospecific reference specificexamples, examples,itit will will be appreciated be appreciated by by those those skilled skilled in inthe theart artthat thethe that invention may invention bebeembodied may embodied in in many other many other

forms in particular forms in particular features featuresofofany anyone oneof ofthe thevarious variousdescribed describedexamples examples may be provided may be providedinin any combinationininany anyofofthe the other other described described examples. examples.Various Variousmodifications modifications and alterations 2025259976

any combination and alterations

to this invention will become apparent to those skilled in the art without departing from the to this invention will become apparent to those skilled in the art without departing from the

scope andspirit scope and spiritofofthis thisinvention. invention. It It should should be understood be understood thatinvention that this this invention is not intended is not intended to to be unduly be undulylimited limited by by the the illustrative illustrative embodiments andexamples embodiments and examplessetsetforth forthherein herein and andthat that such such examples andembodiments examples and embodimentsare are presented presented by way by way of example of example only only with with the scope the scope of the of the

invention intended invention intended to be to be limited limited only only byclaims by the the claims setherein set forth forth as herein as follows. follows.

Claims (13)

19 31 Oct 2025 CLAIMS CLAIMS

1. 1. A method A methodfor forobtaining obtaininga acobalt-enriched cobalt-enrichedmaterial, material, comprising: comprising: (a) (a) providing providing a a discharged discharged lithium lithium ion comprising ion cell cell comprising cobalt; cobalt;

(b) (b) crushing thecell crushing the celltotoform form fragments; fragments;

(c) (c) separating thefragments separating the fragments to obtain to obtain particles particles of less of less than than 4 mm 4 mm in size;in size; and and

(d) (d) treating treatingthe theobtained obtainedparticles with a magnetic a magneticfield of of between between2000 2000and and 8000 8000 Gauss, 2025259976

particles with field Gauss,

so as to so as to select select cobalt-enriched cobalt-enriched material material fromfrom non-cobalt-enriched non-cobalt-enriched material, material,

whereinthe wherein the method methoddoes doesnot notcomprise comprise a heattreatment. a heat treatment.

2. 2. The method of claim 1, wherein the cell is a battery. The method of claim 1, wherein the cell is a battery.

3. 3. The method The methodofofclaim claim1 1ororclaim claim2,2,wherein whereinthe theparticles particles are are between 63µmμm between 63 toto 1.2mmmm 1.2 in in size. size.

4. 4. The method The methodofofany anyone oneofofclaims claims1 1toto3,3,wherein whereinthe theseparating separatingincludes includessieving. sieving.

5. 5. The method The methodofofany anyone oneofofclaims claims1 1toto4,4,wherein whereinthe themagnetic magneticfield fieldisis between betweenabout about3000 3000 and about 5000 and about 5000Gauss. Gauss.

6. 6. The method The methodofofany anyone oneofofclaims claims1 1toto5,5,wherein whereinthe themagnetic magneticfield fieldisis provided providedbybyaa magneticseparator magnetic separatorand/or and/oran aneddy eddycurrent currentdevice. device.

7. 7. The method The methodofofclaim claim6,6,wherein whereinthe themagnetic magnetic separator separator isisa arotating rotating shaft shaft drum. drum.

8. 8. The method The methodofofclaim claim7,7,wherein whereinthe therotating rotatingshaft shaft drum drumhas hasa adiameter diameterofofless less than than about about 30 cm. 30 cm.

9. 9. The method The methodofofany anyone oneofofclaims claims1 1toto8,8,wherein whereinstep step(d) (d) further further comprises treating the comprises treating the

particles with an electrostatic separation device. particles with an electrostatic separation device.

10. 10. The The method method of any of any one one of claims of claims 1 to1 9, to 9, wherein wherein step step (b)(b) furthercomprises further comprises thethe stepofof step

treating the fragments with a solvent. treating the fragments with a solvent.

11. 11. The method The methodofofclaim claim10, 10,wherein wherein thesolvent the solventisisN-methyl-2-pyrrolidone N-methyl-2-pyrrolidone (NMP). (NMP).

20 31 Oct 2025

12. 12. A productobtained A product obtainedfrom fromthe themethod methodof of any any one one of of claims claims 1 to11. 1 to 11.

13. 13. AnAn apparatus apparatus forfor obtaining obtaining a cobalt-enriched a cobalt-enriched material material from from a discharged a discharged lithium lithium ionion cell cell

comprising cobalt, the comprising cobalt, the apparatus comprising:aa crushing apparatus comprising: crushingdevice; device; aa sieving sieving device device and and aa magnetic magnetic device; wherein device; wherein thethe sieving sieving device device is adapted is adapted to obtain to obtain particles particles of less of less than than 4 mm 4 mmthein size, the in size,

magneticdevice magnetic deviceisis adapted adaptedto to generate generate aa magnetic magneticfield field of of between 2000and between 2000 and8000 8000 Gauss, Gauss, andand

the apparatus does not include a heating device. 2025259976

the apparatus does not include a heating device.

Vincent Huang Vincent Huang Patent Patent Attorneys Attorneys for forthe theApplicant/Nominated Applicant/Nominated Person Person

SPRUSON SPRUSON && FERGUSON FERGUSON