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WO2024107207A1 - Récupération de lithium à partir de batteries au lithium-ion - Google Patents

Récupération de lithium à partir de batteries au lithium-ion Download PDF

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Publication number
WO2024107207A1
WO2024107207A1 PCT/US2022/050478 US2022050478W WO2024107207A1 WO 2024107207 A1 WO2024107207 A1 WO 2024107207A1 US 2022050478 W US2022050478 W US 2022050478W WO 2024107207 A1 WO2024107207 A1 WO 2024107207A1
Authority
WO
WIPO (PCT)
Prior art keywords
lithium
black mass
temperature
solution
lithium carbonate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2022/050478
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English (en)
Inventor
Kee-Chan Kim
Eric GRATZ
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ascend Elements Inc
Original Assignee
Ascend Elements Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ascend Elements Inc filed Critical Ascend Elements Inc
Priority to PCT/US2022/050478 priority Critical patent/WO2024107207A1/fr
Publication of WO2024107207A1 publication Critical patent/WO2024107207A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/54—Reclaiming serviceable parts of waste accumulators
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01D—COMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
    • C01D15/00—Lithium compounds
    • C01D15/02—Oxides; Hydroxides
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01D—COMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
    • C01D15/00—Lithium compounds
    • C01D15/08—Carbonates; Bicarbonates
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00—Preliminary treatment of ores or scrap
    • C22B1/02—Roasting processes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B26/00—Obtaining alkali, alkaline earth metals or magnesium
    • C22B26/10—Obtaining alkali metals
    • C22B26/12—Obtaining lithium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/001—Dry processes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/005—Separation by a physical processing technique only, e.g. by mechanical breaking
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/006—Wet processes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/20—Recycling

Definitions

  • Li-ion batteries are a preferred chemistry for secondary (rechargeable) batteries in high discharge applications such as electrical vehicles (EVs) and power tools where electric motors are called upon for rapid acceleration.
  • Li-ion batteries include a charge material, conductive powder and binder applied to or deposited on a current collector, typically a planar sheet of copper or aluminum.
  • the charge material includes anode material, typically graphite or carbon, and cathode material, which includes a predetermined ratio of metals such as lithium, nickel, manganese, cobalt, aluminum, iron and phosphorous, defining a so-called “battery chemistry” of the Li-ion cells.
  • Lithium recovery from a recycled stream of Lithium-Ion (Li-ion) batteries includes roasting a black mass of comingled charge material in a partial oxygen environment, during which carbon from anode material in the black mass combines with lithium from cathode material in the black mass to form lithium carbonate.
  • a subsequent purification upgrades the recycled lithium carbonate from industrial to battery grade.
  • a balance of roasting temperatures and available oxygen causes a sequence of reactions to first form lithium oxide at the temperature of roasting and a second reaction to combine Li with the oxygen and anode carbon without requiring the addition of separate carbon sources such as activated carbon to supplement the production of lithium carbonate.
  • Configurations herein are based, in part, on the observation that lithium recovery is beneficial to battery recycling for cost reduction, as opposed to sourcing refined stock of pure lithium.
  • conventional approaches to Li recovery suffer from the shortcoming that carbon, already readily available in the anode material of the recycling stream, is supplemented with added sources of carbon, such as activated carbon, for yielding Li. This requires additional carbon resources for extracting the Li and leaves additional carbon in the recycling stream that would need to be removed at subsequent recycling steps.
  • configurations herein substantially overcome the shortcomings of conventional added carbon approaches by a partial oxygen roasting that consumes the carbon already present in the black mass from anode material but does not interfere with the thermal reduction of the cathode material for recycling lithium as lithium carbonate.
  • An example configuration employs NMC (Ni, Mn, Co) batteries for recovering lithium from a recycling stream by roasting a black mass from the recycling stream in a partial oxygen environment at a temperature selected for reductive decomposition of the cathode material and reacting carbon in the anode material with lithium in the cathode material, and then leaching the lithium from the roasted black mass for forming a lithium leach solution.
  • Lithium is recovered by heating the lithium leach solution for precipitating the lithium based on decreased solubility of the leached lithium at the increased temperature, as the Li precipitates out of solution as Li2CC>3 at increased temperatures.
  • Fig. 1 is a flowchart of partial oxygen roasting for Li recovery as disclosed herein;
  • Fig. 2 is a flowchart of purification of the Li from the leachate of Fig. 1 ;
  • Fig. 3 is a results chart of the analysis of the leachate of Figs. 1;
  • Fig. 4 is a results chart of the Li purification of Fig. 2;
  • Fig. 5 shows the results of iterative leach cycles.
  • modem secondary (rechargeable) batteries employ metals such as Ni, Mn, Co and Al along with a binder and conductive material as a cathode material, and graphite or similar forms of carbon as an anode material. Recycling is typically commenced with discharging and physical dismantling, crushing, and/or agitating the battery casing structure to yield a granular, comingled stock referred to as “black mass,” including cathode, anode, and various casing and conductor materials. Retired or defective electric vehicle (EV) batteries are often sought for their large volume of raw charge materials for recycling.
  • EV electric vehicle
  • roasting approaches to lithium recycling employ an inert or reducing gas environment and include the addition of a carbon source, such as activated carbon, despite a relative abundance of carbon from the anode material.
  • Configurations herein employ a partial oxygen environment that utilizes the carbon already present in the black mass as the carbon source, but does not interfere with the thermal reduction and decomposition of the cathode material.
  • Configurations discussed below demonstrate that a small amount of oxygen in the partial O2 environment effectively activates the carbon in the anode material source, without harming the thermal reduction/decomposition in the NMC cathode material, thereby obviating the need for additional activated carbon.
  • the black mass from recycled Li-ion batteries includes a mixture of anode and cathode charge materials, as well as impurities such as copper, aluminum and iron used in the physical battery casing and contacts that interconnect the individual cells, typically in a shape that engages the EV that uses the battery pack.
  • This black mass therefore contains a particulate form of battery materials including charge material metals, carbon/graphite, lithium and electrolyte, in a somewhat variable ratio based on the arrangement and type of the batteries in the source recycling stream. Arrangement by battery chemistry and/or vehicle manufacturer may or may not be well defined. The presence of substantial amounts of lithium from the cathode and of carbon from the anode can be expected, however, regardless of the precise battery chemistry.
  • roasting the black mass from recycled lithium-ion batteries facilitates recovery of valuable metals, such as Li, Ni, Mn and Co, from the spent batteries.
  • Conventional approaches employ an inert environment (N2 or Ar) or reducing gas environment (H2 or CH4) in order to reduce the active transition metal ions of the cathode materials.
  • N2 or Ar inert environment
  • H2 or CH4 reducing gas environment
  • higher roasting temperatures are often required to complete the reduction, and also activated carbon is added for boosting the carbothermal reduction, even though the black mass already has plenty of carbon from the anode graphite, increasing energy consumption and operating expense.
  • an explosive or highly flammable gas component requires strict safety control, imposing additional costs for the environment gas composition.
  • Roasting black mass in an inert or reducing environmental atmosphere also often causes further reduction of the transition metals forming their alloys, which is problematic for the transition recovery in downstream recycling targeting the charge material metals.
  • Fig. 1 is a flowchart of an embodiment of a method of partial oxygen roasting for Li recovery disclosed herein.
  • the roasting process 100 includes, at step 102, roasting a black mass, provided from a lithium-ion battery recycling stream, in a partial oxygen environment at a temperature that is greater than 500°C.
  • the temperature can be based on the thermal reduction/decomposition of the cathode material and reacting carbon in the anode material with lithium in the cathode material.
  • the black mass typically results from a recycling stream of Ni, Mn, Co (NMC) batteries.
  • the roasting converts the lithium in the black mass to lithium carbonate from the available carbon in the black mass from the anode material.
  • the partial oxygen environment is defined by an oxygen environment having a lower concentration of oxygen than atmospheric oxygen and a nitrogen concentration greater than atmospheric nitrogen.
  • the partial oxygen percentage is 2-10 %, preferably 3-5 % and is balanced with an inert gas such as nitrogen or argon, defining an environment with less oxygen and more nitrogen (or other inert gas) than an ambient atmosphere (i.e., air).
  • the roasting temperature can be between 550 °C and 700 °C, preferably between 575 °C and 650 °C, which causes the carbon already present from the anode to begin to react with the oxygen (below 500°C, the carbon would be expected to remain inert).
  • roasting the black mass is believed to cause a carbothermal reaction with the oxygen in the partial oxygen environment in an absence of additional activated carbon.
  • the cathode material is exposed to > 500°C, the transition metals in the cathode material are also thermally reduced and decomposed, and the lithium in the cathode is initially transformed to lithium oxide.
  • the Li2O is converted to Li2CO3 when carbon and oxygen is available.
  • the reactions (1) and (2) are very fast and likely occur almost simultaneously:
  • the thermal treatment time of the roasting can vary by is typically between 10 minutes and 120 minutes, preferably 30-60 minutes.
  • the lithium compound can be leached from the roasted black mass by agitating it in deionized water, as depicted at step 104, forming an aqueous lithium leach solution.
  • the lithium employed in the disclosed approach is a lithium salt combined with charge material metals in the recycling source, and precipitated as lithium salts as the yielded lithium product.
  • the lithium product, Li2CO3 is the only water leachable compound in the roasted black mass; the remainder is not soluble in water. Therefore, lithium carbonate can be selectively leached from the roasted black mass using deionized water. Filtering of the lithium leach solution separates insoluble materials from the dissolved lithium salts.
  • the electrolyte typically LiPF6
  • Sodium and sulfur impurities may emerge from environmental conditions, which are avoidable by controlling the environment. Analysis of the leachate and product are shown below in Fig. 3.
  • the amount of deionized water added for leaching can be varied.
  • the ratio of water to the thermal treated black mass is approximately 5-40 by weight, preferably 15-20.
  • the lithium leaching temperature is maintained at approximately 5-40°C, preferably about 20-30°C, and the agitation time is 10-240 minutes, preferably 20-60 minutes.
  • the solubility of Li2CO3 changes inversely with temperature, in contrast to most solutes. Therefore, recovery of the lithium can occur by heating the lithium leach solution, thereby precipitating the lithium carbonate based on decreased solubility of the leached lithium carbonate at the increased temperature.
  • the leached Li2CO3 is harvested by separating unleached solids out by filtration, at step 108, followed by heating of the filtrate to > 90°C for 10 -120 minutes, preferably 30-60 minutes, as shown at step 114.
  • the filtered unleached solids prior to heating of the leach solution include delithiated NMC, typically decomposed NMC oxides such as NiO, MnO, Mn3O4, CoO, CO3O4, etc. and unreacted graphite, as disclosed at step 110.
  • the filtered solids can then be fed to NMC and graphite recovery streams for further treatment, as depicted at step 112.
  • Filtering harvests the desired lithium product, lithium carbonate in the example of Fig. 1, as depicted at step 116.
  • the aqueous filtrate may be recycled back to step 104 for a leaching cycle.
  • the resulting filtered lithium carbonate solids, as depicted at step 118, is dried in a granular form, as shown at step 120.
  • the dried lithium carbonate can then be further purified, if desired, an example of which is shown in Fig. 2.
  • the lithium carbonate product from step 120 of Fig. 1 is at least technical grade (> 99% purity) and can be improved to battery grade by a simple purification 200.
  • lithium carbonate solubility is increased 5 times or more due to the conversion of less soluble lithium carbonate to highly soluble lithium bicarbonate.
  • impurities do not dissolve and stay in the solid state for separation by filtration, shown by equation 3 :
  • Equation 3 represents the combination of carbon dioxide with the recovered lithium carbonate for precipitating purified lithium carbonate.
  • the recovered lithium carbonate is dissolved in a water to form a solution.
  • the Li 2 CO 3 is dissolved in DI (deionized) water by carbonation, depicted at step 204 (dissolving CO 2 in the solution), forming a carbonated solution.
  • impurities in the lithium carbonate remain as solids.
  • the impurity solids may be removed by microfiltration, using a filter membrane of between 0.1-0.45 pm, as shown at step 206.
  • Li 2 CO 3 is recovered by converting the much more soluble LiHCO 3 to a much less soluble Li 2 CO 3 with heat at greater than 90°C, such as to a temperature of greater than or equal to 95°C for 1 hour, as depicted at step 208.
  • Carbonization may be performed by bubbling the carbon dioxide through or by pressurizing carbon dioxide to the water solution of the leached lithium carbonate, and stirring, forming carbonic acid and undissolved solids. When the carbonation is completed, the aqueous solution of lithium bicarbonate achieves a pH between 7.0 - 8.5.
  • Precipitated Li2CO3 by heating the lithium bicarbonate solution is filtered, as depicted at step 210, and the filtered yield at step 212 is dried to form battery grade lithium carbonate, as disclosed at step 214.
  • the resulting lithium carbonate can be readily used as the lithium source in cathode material for recycled cells.
  • Fig. 3 is a results chart of the analysis of the leachate of Fig. 1. Small amounts of sodium, sulfur and aluminum may be removed by the purification of Fig. 2. It should be apparent that the sequence of the process of Figs. 1 and 2 yields battery grade lithium products in the form of lithium carbonate from the black mass of NMC or similar recycled batteries. The remaining black mass includes residual carbon (less than 15% is consumed) and delithiated charge material metals such as Ni, Mn, and Co.
  • Figs. 4 and 5 An example of the above approach is depicted in Figs. 4 and 5.
  • 20 Kg of black mass is roasted at 610 °C for 30 minutes with 3.5-4.5 % O2 balanced with N2 using a pilot rotary kiln.
  • Figs. 4 and 5 50 g of the roasted black mass was added to 1 L of deionized water, and the mixture stirred for 30 minutes at the ambient temperature ( ⁇ 20°C). The solid was then removed by vacuum filtration with 1-pm filter paper. The filtrate was heated to > 90 °C for one hour. While heating the filtrate, Li2CO3 precipitated from the solution due to the low solubility at this higher temperature. The Li2CO3 product is collected via vacuum filtration with 0.45 -pm filter membrane. The filtrate was fed to a subsequent leaching process using the same amount of the roasted black mass by adding a small amount of deionized water lost during the cycle. This cycle was repeated 10 times.
  • the Li2CC>3 product collected above was purified as shown in Fig. 2.
  • 12.6 g of the Li2CC>3 was dispersed in 200 mL of DI water, and CO2 was bubbled through the solution with mechanical stirring of the mixture at 5-20 °C. The CO2 bubbling and stirring was continued until the solution pH reached 7.5-8.0.
  • the undissolved solid was then removed by vacuum filtration using 0.1-0.2 pm filter membrane.
  • the filtrate was heated to > 90 °C to convert highly soluble Li HCO3 to much less soluble Li2CO3.
  • the filtrate was recycled back to the next purification liquor.
  • Fig. 4 is a results chart of the Li purification of Fig. 2. As can be seen, substantial impurities are removed by the purification process, particularly for aluminum and sodium.
  • Fig. 5 shows the results of 10 iterative cycles of Li recovery as in Fig. 1 to generate the interim lithium carbonate product prior to the purification in Fig. 2.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Geology (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Metallurgy (AREA)
  • Environmental & Geological Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Secondary Cells (AREA)

Abstract

Le recyclage du matériau de charge pour une batterie NMC (Ni, Mn, Co) récupère le lithium à partir d'un flux de batterie recyclé par torréfaction d'une masse noire à partir du flux recyclé dans un environnement d'oxygène partiel à une température basée sur la réduction thermique du matériau de cathode et la réaction du carbone dans un matériau d'anode avec du lithium dans le matériau de cathode, puis la lixiviation du lithium à partir de la masse noire torréfiée pour former une solution de lixiviation au lithium. Le lithium est récupéré par chauffage de la solution de lixiviation au lithium, précipitation du carbonate de lithium sur la base d'une solubilité réduite du carbonate de lithium lixivié à la température accrue.
PCT/US2022/050478 2022-11-18 2022-11-18 Récupération de lithium à partir de batteries au lithium-ion Ceased WO2024107207A1 (fr)

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PCT/US2022/050478 WO2024107207A1 (fr) 2022-11-18 2022-11-18 Récupération de lithium à partir de batteries au lithium-ion

Applications Claiming Priority (1)

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PCT/US2022/050478 WO2024107207A1 (fr) 2022-11-18 2022-11-18 Récupération de lithium à partir de batteries au lithium-ion

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001525313A (ja) * 1997-12-09 2001-12-11 リムテック 炭酸リチウムの精製方法
JP2012229471A (ja) * 2011-04-26 2012-11-22 Dowa Eco-System Co Ltd 炭酸リチウムの製造方法及び炭酸リチウムの製造装置
JP2021172537A (ja) * 2020-04-21 2021-11-01 Ｊｘ金属株式会社 水酸化リチウムの製造方法
EP3535803B1 (fr) * 2017-05-30 2022-03-09 Li-Cycle Corp. Procédé, appareil et système de récupération de matériaux à partir de batteries
KR20220078690A (ko) * 2020-03-31 2022-06-10 제이엑스금속주식회사 전지 폐기물의 열처리 방법, 및 리튬 회수 방법

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001525313A (ja) * 1997-12-09 2001-12-11 リムテック 炭酸リチウムの精製方法
JP2012229471A (ja) * 2011-04-26 2012-11-22 Dowa Eco-System Co Ltd 炭酸リチウムの製造方法及び炭酸リチウムの製造装置
EP3535803B1 (fr) * 2017-05-30 2022-03-09 Li-Cycle Corp. Procédé, appareil et système de récupération de matériaux à partir de batteries
KR20220078690A (ko) * 2020-03-31 2022-06-10 제이엑스금속주식회사 전지 폐기물의 열처리 방법, 및 리튬 회수 방법
JP2021172537A (ja) * 2020-04-21 2021-11-01 Ｊｘ金属株式会社 水酸化リチウムの製造方法

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