Description:TECHNICAL FIELD
[0001] The present disclosure relates, in general, to battery recycling, and more specifically, relates to a system and method for recovery of metal current collectors from depleted lithium-ion batteries (LIBs).

BACKGROUND
[0002] The surge in electric vehicle (EV) adoption underscores the critical need for recycling to underpin the sustainability of electric transportation. As the EV industry expands, there is a growing imperative to advance recycling processes and infrastructure to effectively manage the challenges and opportunities posed by electric vehicle batteries. This imperative arises from the escalating production of electric vehicles, which, according to estimates from the International Energy Agency, yielded approximately 500,000 tons to (5 million tons) of lithium-ion battery (LIB) waste in 2019 alone, with projections indicating a potential increase to 8 million tons by 2040. Recycling these batteries not only mitigates waste but also facilitates the recovery of valuable metals such as Cobalt (Co), Manganese (Mn), Nickel (Ni), Lithium (Li), Copper (Cu), and Aluminum (Al), thereby reducing reliance on primary mining, conserving resources, and curbing environmental impacts associated with mining and metal production. Moreover, recycling endeavors aid in the retrieval of valuable materials while curbing the disposal of hazardous waste from used batteries. The LIB recycling process typically encompasses discharge, disassembly, shredding-crushing, and screening, employing mechanical separation techniques including pneumatic separation, magnetic separation, eddy current selection, high-voltage electrostatic selection, and gravity separation.
[0003] The current recycling landscape for lithium-ion batteries suffers from several limitations. Firstly, while most recycling processes prioritize metals such as Co, Mn, Ni, and Li, they often overlook the significance of current collectors, which account for 15% of cell weight and 10% of cell cost. Secondly, there is a notable scarcity of literature concerning the recovery of Cu and Au, with a lack of systematic studies on large-scale recycling endeavors. Lastly, conventional methods for Cu and Al recovery typically rely on the utilization of substantial quantities of strong acids.
[0004] The present situation in the electric vehicle (EV) sector involves a notable demand for copper (Cu) and aluminum (Al), primarily due to their extensive use in EV components. Anticipated advancements and expansion in EV production are expected to escalate the demand for Cu and Al in the forthcoming years.
[0005] Therefore, it is desired to overcome the drawbacks, shortcomings, and limitations associated with existing solutions, and develop a process for recovering Cu and Al foil by combining various separation techniques, resulting in the retrieval of metals within the range of 95% to 98%.

OBJECTS OF THE PRESENT DISCLOSURE
[0006] An object of the present disclosure relates, in general, to battery recycling, and more specifically, relates to a system and method for recovery of metal current collectors from depleted lithium-ion batteries (LIBs).
[0007] Another object of the present disclosure is to provide a system for environmental sustainability by recovering Cu and Al from depleted LIBs, thereby reducing energy consumption and greenhouse gas emissions.
[0008] Another object of the present disclosure is to provide a system for resource conservation by recovering Cu and Al from depleted batteries, which can then be reused in various applications, thus reducing the need for new metal extraction.
[0009] Another object of the present disclosure is to provide a system for economic viability through its high recovery rate of Cu and Al, ranging from 95% to 98%, combined with achieved purity levels of 98% to 99%.
[0010] Another object of the present disclosure is to provide a system for reduced waste by effectively recovering Cu and Al current collectors from depleted LIBs.
[0011] Yet another object of the present disclosure is to provide a system that incorporates advanced sorting, discharging, shredding, and separation units, along with optimized parameters such as air-flow, pressure, and particle size, thereby enhancing the efficiency and effectiveness of the metal recovery process in the recycling industry.

SUMMARY
[0012] The present disclosure relates in general, to battery recycling, and more specifically, relates to a system and method for recovery of metal current collectors from depleted lithium-ion batteries (LIBs). The main objective of the present disclosure is to overcome the drawbacks, limitations, and shortcomings of the existing system and solution, by offering a chemistry-agnostic process capable of recycling lithium-ion batteries of various chemistries and form factors. Moreover, it introduces innovative approaches to integrate Cu and Al recovery seamlessly into the broader recycling process, enhancing overall material recovery rates while minimizing environmental impact. Additionally, the invention incorporates a combination of gravity separation techniques to efficiently sort materials based on their weight and aerodynamic properties.
[0013] The present disclosure provides a system for recycling metals from depleted batteries including a battery processor configured to mechanically shred depleted batteries, yielding black mass containing cathode and anode active material alongside binders and recycle electrolyte solvents. A plastic processor utilizes pneumatic conveying air classifier to segregate plastic from metals, steel casing, and iron. A steel and iron processing unit incorporates an eddy current for segregating and recovering steel and iron materials. A metal separation unit employs various pulverizers and gravity separators to classify and separate metals from the depleted batteries, with recovered metals exhibiting a metal assay within a predefined range of 98-99%.
[0014] The batteries processed by the system include lithium-ion batteries. The battery processor includes a dismantling and sorting unit, a discharging unit, a shredding unit, and a separation unit for processing battery cells. A black mass recovery unit is employed to recover black mass from shredded cell materials, achieving a recovery rate within the range of 97-99%. Electrolyte solvents from the batteries are recovered in an electrolyte recovery unit, ensuring a closed-loop arrangement for solvent collection without leakage.
[0015] The plastic processor comprises sorting and separating units for segregating plastic from metals, steel casing, and iron, with the recovered plastic passing through a plastic recovery unit. Steel and iron materials recovered by the steel and iron processing unit undergo further processing in respective iron and steel recovery units, achieving a recovery rate for steel casing within the range of 98-99%.
[0016] Separated metals pertaining to Cu and Al from the metal separation unit are processed in respective metal processing units. Each metal processing unit includes a washing unit, a drying unit, a briquetting unit, and a high-temperature furnace for processing copper and aluminum metals, with recovery rates for Cu and Al current collectors falling within the range of 95-90%.
[0017] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The following drawings form part of the present specification and are included to further illustrate aspects of the present disclosure. The disclosure may be better understood by reference to the drawings in combination with the detailed description of the specific embodiments presented herein.
[0019] FIG. 1 illustrates an exemplary view of recycling system, in accordance with an embodiment of the present disclosure.
[0020] FIG. 2 illustrates an exemplary flow chart of a method for recycling metals from depleted batteries, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0021] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0022] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0023] The present disclosure relates, in general, to battery recycling, and more specifically, relates to a system and method for recovery of metal current collectors from depleted lithium-ion batteries (LIBs). The term "depleted Lithium-ion Batteries (LIBs)" refers to lithium-ion batteries that have reached the end of their useful life or are no longer capable of delivering the desired performance due to factors such as reduced capacity, degradation of components, or physical damage. These batteries are typically removed from use and are considered "depleted" as they are no longer suitable for their intended applications.
[0024] The proposed system disclosed in the present disclosure overcomes the drawbacks, shortcomings, and limitations associated with the conventional system by providing a system for recycling metals from depleted batteries, including a battery processor configured to mechanically shred depleted batteries to produce black mass containing cathode and anode active material along with binders and recycle electrolyte solvents present in depleted batteries. A plastic processor employs pneumatic conveying air classifier to segregate plastic from metals, steel casing, and iron.
[0025] Additionally, a steel and iron processing unit incorporates an eddy current with variable magnetic strength to segregate and recover steel and iron materials from the depleted batteries. Furthermore, a metal separation unit has different sets of pulverizers and gravity separators for size classification and separation of the metals from the depleted batteries, with recovered metals exhibiting a metal assay falling within a predefined range of 98-99%.
[0026] The system accommodates various types of batteries, including lithium-ion batteries, including Nickel Manganese Cobalt (NMC), Lithium Iron Phosphate (LFP), Lithium Cobalt Oxide (LCO), Lithium Titanate Oxide (LTO), Lithium Manganese Oxide (LMO) chemistry, including different form factors including cylindrical of different sizes-18650, 221700, 26650, 32600, prismatic, pouch and includes units within the battery processor for dismantling and sorting battery cells, discharging remaining charge, shredding battery cells, and separating black mass from various materials and plastics including separators. It also includes units for recovering black mass and electrolyte solvents, sorting and recovering plastic, steel, and iron materials, as well as metal processing units configured for processing copper and aluminum metals. Each metal processing unit includes washing, drying, briquetting, and high-temperature furnace units for metal processing. The present disclosure can be described in enabling detail in the following examples, which may represent more than one embodiment of the present disclosure.
[0027] The advantages achieved by the system of the present disclosure can be clear from the embodiments provided herein. The system is designed for environmental sustainability by recovering copper (Cu) and aluminum (Al) from depleted lithium-ion batteries (LIBs), thereby contributing to the reduction of energy consumption and greenhouse gas emissions. Additionally, the system promotes resource conservation by enabling the recovery of Cu and Al from depleted batteries, which can be reused in various applications, thus lessening the demand for new metal extraction. The invention further emphasizes economic viability by achieving high recovery rates of Cu and Al, ranging from 95% to 98%, coupled with purity levels of 98% to 99%. Moreover, the system effectively reduces waste by recovering Cu and Al current collectors from depleted LIBs. Through the integration of advanced sorting, discharging, shredding, and separation units, alongside optimized parameters such as air-flow, pressure, and particle size, the present disclosure enhances the efficiency and effectiveness of metal recovery processes within the recycling industry. Furthermore, the system ensures the quality and safety of individual cells while managing battery packs, facilitating the assembly of high-performance battery packs for diverse applications. Moreover, the present disclosure mitigates the risk of thermal runaway, preventing potential explosions or fires associated with battery mismanagement. The description of terms and features related to the present disclosure shall be clear from the embodiments that are illustrated and described; however, the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents of the embodiments are possible within the scope of the present disclosure. Additionally, the invention can include other embodiments that are within the scope of the claims but are not described in detail with respect to the following description.
[0028] FIG. 1 illustrates an exemplary view of recycling system, in accordance with an embodiment of the present disclosure.
[0029] Referring to FIG. 1, recycling system 100 (also referred to as system 100, herein) disclosed to recover metals from depleted batteries achieving a recovery range of 95% to 98%. In an exemplary embodiment, the metals selected from copper (Cu) and aluminum (Al) from depleted Lithium-ion Batteries (LIBs). The system 100 can include a series of interconnected units. The series of interconnected units can include a depleted battery processor 102 that encompasses battery dismantling and sorting unit (104-1), discharging unit (104-2), shredding unit (104-3), and separation unit (104-4), resulting in the production of black mass containing cathode and anode active materials along with binders. The fine black mass is transferred to a dedicated black mass recovery unit (106), and an electrolyte recovery unit (108) is utilized to recover electrolyte solvents.
[0030] The system 100 further includes a plastic processor 110 that includes a sorting unit 112-1 and a plastic separation unit 112-2 that segregates plastic from Al-Cu, steel casing, and iron. A steel and iron processing unit 114 to process, segregate and recover stainless steel and iron materials efficiently. The remaining Al-Cu material undergoes size classification and separation in a metal separation unit (116) that processes the metals such as Cu and Al in dedicated Cu and Al processing units (118-1, 118-2).
[0031] In an embodiment, the battery dismantling and sorting unit 104-1 is responsible for dismantling the battery cells/packs and sorting the individual battery cells based on an in-house protocol. The battery packs typically consist of several individual cells, casing, wiring and the like. The dismantling process likely includes steps such as removing the casing, disconnecting wiring, and separating the individual cells. The in-house protocol likely includes specific criteria and procedures for sorting the cells. These criteria could be based on various factors such as cell capacity, voltage, impedance, internal resistance, and possibly even the manufacturer's specifications. The dismantling process likely includes chemistry based seggragation including NMC, LFP, LCO, LTO, LMO chemistry. The dismantly process likely to includes the form factor based separation including cylindrical of different sizes-18650, 221700, 26650, 32600, prismatic, pouch etc. The protocol may also dictate the use of specialized equipment, testing procedures, and safety measures to ensure accurate and efficient sorting. The battery dismantling and sorting unit 104-1 is essential for efficiently managing battery packs, ensuring the quality and safety of individual cells, and facilitating the assembly of high-performance battery packs for various applications.
[0032] The discharging unit 102-2 neutralizes any remaining charge in the individual battery cells to prevent explosions during subsequent shredding processes. The discharging unit 102-2 serves a critical function in the recycling process by ensuring the safety of subsequent steps, particularly during the shredding process. The discharging unit is salt-solution including different wt% of salt mixture, ranging 5-20%. The salt-solution unit contains different salt including any one or combination of two or more including Sodium Chloride (NaCl), Sodium Carbonate (Na2CO3), Sodium Sulfate (Na2SO4), Magnesium Chloride (MgCl2), Magnesium Sulfate (MgSO4), Sodium Nitrate (NaNO3) etc. LIBs often retain residual electrical charge even after they have been taken out of use. This residual charge can pose a significant safety risk, as it may lead to thermal runaway – a rapid and uncontrollable increase in temperature – when subjected to physical processes such as shredding. To mitigate this risk, the discharging unit is tasked with neutralizing any remaining charge present in the cells. This neutralization process involves intentionally draining the electrical charge from the cells until they reach a safe voltage level. By neutralizing the electrical charge in the cells before shredding, the discharging unit 102-2 effectively prevents the risk of thermal runaway and subsequent explosions or fires.
[0033] The shredding unit 104-3 includes shredders and hammers used to extract and break down the individual battery cells into small pieces. The shredding unit 104-3 typically consists of specialized shredders and hammers designed specifically for processing LIBs. These shredders are equipped with sharp blades or hammers that effectively crush and pulverize the battery cells into smaller fragments. The size of the resulting pieces may vary depending on the specific requirements of the recycling process. The shredding unit 104-3 plays a crucial role in the initial stage of LIB recycling, breaking down the batteries into smaller pieces to facilitate further processing and maximize the recovery of valuable materials.
[0034] The separation unit 104-4 can include a pneumatic conveying system, centrifugal separator, bag-filter, and gyro-screens to separate the shredded cell material into different components such as black mass (BM), Cu-Al foil, casing, and other materials. The shredded cell material, comprising casing, plastic, Cu-Al current collector, black mass (BM), and other components, is conveyed pneumatically to a series of interconnected centrifugal separators. Within these separators, the black mass and Cu-Al foil, casing, and other components are pushed to the outer edges at varying stages due to centrifugal force, while electrolytes are directed to a heat-exchanger for separation. Subsequently, the components emerging from the centrifugal separator proceed through multiple gyro-screens equipped with different wired mesh configurations and aligned in the series to further separate the black mass from Al-Cu, plastic separator, and casing materials. The fine black mass is subsequently isolated from the Al-Cu, plastic separator, and casing materials and transferred to a dedicated black mass recovery unit 106.
[0035] The black mass recovery unit 106 can include silos, bag filters, and scrubbers to recover the black mass from the shredded material. The black mass recovery unit 106 recovers valuable materials from the black mass generated during shredding and separation stages. The silos provide storage capacity, the bag filters remove particulate matter, and the scrubbers help control emissions, contributing to a safe and environmentally responsible LIB recycling process. Further, the electrolyte recovery unit 108 recovers and recycles the electrolyte solvents present in depleted LIBs. The electrolyte recovery unit 108 utilizes a closed-loop arrangement of heat exchanger and solvent collection columns to recover electrolyte solvents without any leakage.
[0036] In an embodiment, the plastic processor 110 employs pneumatic conveying (also referred to as air flow controlled pneumatic conveying air classifier) to move materials of the depleted batteries within the system to segregate plastic from metals i.e., Al-Cu, steel casing, and iron. The plastic processor 110 can include the sorting unit 112-1 to segregate plastic, Al-Cu, steel casing, and iron and the separating unit 112-2 for separating plastic from Al-Cu, steel casing, and iron, and passing through a plastic recovery unit 120. The air classifier operates based on the principle of the aerodynamic behavior of particles. The aerodynamically lighter materials are carried to the top by the airflow that is led through the classifier and heavier materials fall to the bottom.
[0037] In another embodiment, the steel and iron processing unit 114 incorporates an eddy current separator with variable magnetic strength to segregate and recover steel and iron materials from the depleted batteries. The steel and iron processing unit 114 utilizes eddy current and steel separation unit to segregate and recover steel and iron materials efficiently. The segregated steel and iron materials from the steel and iron processing unit 114 are passed through an iron recovery unit 122-1 and steel recovery unit 122-2 respectively.
[0038] The eddy current separator operates based on electromagnetic induction principles to separate non-ferrous metals i.e., aluminum and copper by their different electric conductivities. The separator generates an induced magnetic flux, the strength of which depends on the conductivity of the material. The separation occurs as the induced magnetic flux interacts with the magnetic field of a rotating drum. The scrap particles are conveyed along a conveyor belt and are thrown off with varying energies, leading to different trajectories based on conductivity. The system efficiently segregates materials, passing iron and steel to separate recovery units. The remained Al-Cu passed through the metal separation unit 116.
[0039] The metal separation unit 116 having different sets of pulverizers and gravity separators for size classification and separation of the metals from the depleted batteries, with recovered metals exhibiting a metal assay falling within a predefined range of 98-99%. The remaining Al-Cu material undergoes size classification and separation in the metal separation unit 110 before gravity separation and subsequent processing in dedicated Cu and Al processing units (118-1, 118-2). These processing units include washing, drying, and briquetting stages, with metal assay of recovered Cu and Al in the range of 98-99%. The briquetting process involves the use of hydraulic pressure to compress metal foil/chips into high-density pallets, which are then melted in induction furnaces to produce metal ingots.
[0040] The pulverizer is configured for micronizing copper (Cu) and aluminum (Al) through air grinding and spheroidizing to facilitate subsequent gravity separation. The gravity separator for size classification and separation of micronized Cu and Al. Following gravity separation, Cu and Al are transferred to respective processing units i.e., copper metal processing unit (118-1) and aluminum metal processing unit (118-2).
[0041] Each metal processing unit of Cu and Al includes:
a. Washing unit that utilizes high-pressure spray washing to clean metal surfaces and ensure the absence of metal impurities.
b. Drying unit that is equipped with temperature and pressure controllers for thorough drying of the washed metals.
c. Briquetting unit that employs a high-density metal chip briquetting machine to compress metal foil/chips into compact pallets through hydraulic pressure, resulting in solid blocks with high density. The working principle of the briquetting machine is to use hydraulic pressure to press the metal which can produce plastic deformation into a solid block with high density.
d. High-temperature furnace that is used for melting the high-density briquettes above their respective melting points to produce metal ingots. The recovered Cu and Al metals exhibit a metal assay in the range of 98-99%.
[0042] The process enables the attainment of Cu and Al purity levels within the range of 98% to 99%. Utilizing pneumatically connected sorting, discharging, shredding, and various separation units, the system 100 facilitates the recovery of Cu and Al current collectors for reuse across diverse applications. The complexity of the recovery process is heightened by factors such as the varied sizes of Cu and Al thin foils, chemical residues on metal surfaces, and altered shapes post-shredding and separation. Optimal parameters, including airflow and pressure, particle size, and diverse separation techniques, have been optimized to render the process economically viable for large-scale processing.
[0043] For example, the system for recycling metals from spent batteries is disclosed herein, particularly suited for lithium-ion batteries commonly found in portable electronic devices such as smartphones and laptops. The system includes several units designed to efficiently process and recover metals from spent/depleted batteries. At the core of the system is the battery dismantling & sorting unit, responsible for dismantling battery packs and sorting individual cells for processing. Following this, the discharging unit neutralizes the electrical charge within the cells to prevent potential explosions during subsequent processing.
[0044] The shredding unit utilizes shredders and hammers to shred cells into small pieces, facilitating further processing. Subsequently, the shredded material is conveyed pneumatically to the separation unit, which employs an assembly of centrifugal separators. These separators efficiently segregate different materials such as black mass, Cu-Al foil, casing, and electrolytes based on their varying mass and centrifugal force. The separated black mass undergoes additional recovery processes in the black mass recovery unit, which includes silos, bag filters, and scrubbers. Meanwhile, the plastic processing unit utilizes an airflow-controlled pneumatic conveying Air-classifier to segregate plastic from other materials like Al-Cu, steel casing, and iron, enabling separate recovery of plastic.
[0045] The steel and iron separation unit incorporates an eddy current-based system with variable magnetic strength to segregate steel and iron materials. These materials are collected separately in iron and steel recovery units. Remaining Cu-Al materials from the separation process pass through a Cu-Al metal separation unit, where they undergo size classification and separation using pulverizers and gravity separators. Subsequently, the copper and aluminum metal processing units employ washing, drying, briquetting, and high-temperature furnaces to produce metal ingots/blocks with high purity and density. Processes such as high-pressure spray washing and hydraulic briquetting ensure the quality of the recovered metals.
[0046] Thus, the present invention overcomes the drawbacks, shortcomings, and limitations associated with existing solutions, and provides a system configured for environmental sustainability by recovering copper (Cu) and aluminium (Al) from depleted lithium-ion batteries (LIBs), thereby contributing to the reduction of energy consumption and greenhouse gas emissions. Additionally, the system promotes resource conservation by enabling the recovery of Cu and Al from depleted batteries, which can be reused in various applications, thus lessening the demand for new metal extraction. The present disclosure further emphasizes economic viability by achieving high recovery rates of Cu and Al, ranging from 95% to 98%, coupled with purity levels of 98% to 99%. Moreover, the system effectively reduces waste by recovering Cu and Al current collectors from depleted LIBs. Through the integration of advanced sorting, discharging, shredding, and separation units, alongside optimized parameters such as air-flow, pressure, and particle size, the invention enhances the efficiency and effectiveness of metal recovery processes within the recycling industry. Furthermore, the system ensures the quality and safety of individual cells while managing battery packs, facilitating the assembly of high-performance battery packs for diverse applications. Moreover, the invention mitigates the risk of thermal runaway, preventing potential explosions or fires associated with battery mismanagement.
[0047] FIG. 2 illustrates an exemplary flow chart of a method for recycling metals from depleted batteries, in accordance with an embodiment of the present disclosure.
[0048] Referring to FIG. 2, the method 200 includes block 202, where depleted batteries are mechanically shredded using the battery processor 102 to produce black mass containing cathode and anode active material along with binders and recycle electrolyte solvents present in depleted batteries.
[0049] At block 204, pneumatic conveying air classifier is employed within the system using the plastic processor 110 to move materials of the depleted batteries and to segregate plastic from metals, steel casing, and iron.
[0050] At block 206, the steel and iron processing unit incorporates an eddy current separator with variable magnetic strength to segregate and recover steel and iron materials from the depleted batteries. At block 208, utilizing a metal separation unit 116 comprising different sets of pulverizers and gravity separators for size classification and separation of the metals from the depleted batteries, with recovered metals exhibiting a metal assay falling within a predefined range of 98-99%.
[0051] It will be apparent to those skilled in the art that the system 100 of the disclosure may be provided using some or all of the mentioned features and components without departing from the scope of the present disclosure. While various embodiments of the present disclosure have been illustrated and described herein, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure, as described in the claims.

ADVANTAGES OF THE PRESENT INVENTION
[0052] The present invention provides a system for environmental sustainability by recovering Cu and Al from depleted LIBs, thereby reducing energy consumption and greenhouse gas emissions.
[0053] The present invention provides a system for resource conservation by recovering Cu and Al from depleted batteries, which can then be reused in various applications, thus reducing the need for new metal extraction.
[0054] The present invention provides a system for economic viability through its high recovery rate of Cu and Al, ranging from 95% to 98%, combined with achieved purity levels of 98% to 99%.
[0055] The present invention provides a system for reduced waste by effectively recovering Cu and Al current collectors from depleted LIBs.
[0056] The present invention provides a system that incorporates advanced sorting, discharging, shredding, and separation units, along with optimized parameters such as airflow, pressure, and particle size, thereby enhancing the efficiency and effectiveness of the metal recovery process in the recycling industry.
[0057] The present invention provides a system that efficiently manages battery packs, ensuring the quality and safety of individual cells, and facilitating the assembly of high-performance battery packs for various applications.
[0058] The present invention provides a system that prevents the risk of thermal runaway and subsequent explosions or fires.
, Claims:1. A system (100) for recycling metals from depleted batteries, the system comprising:
a battery processor (102) configured to mechanically shred depleted batteries to produce black mass containing cathode and anode active material along with binders and recycle electrolyte solvents present in the depleted batteries;
a plastic processor (110) employing pneumatic conveying air classifier to segregate plastic from metals, steel casing, and iron;
a steel and iron processing unit (114) incorporating an eddy current separator with variable magnetic strength to segregate and recover steel and iron materials from the depleted batteries; and
a metal separation unit (116) having different sets of pulverizers and gravity separators for size classification and separation of the metals from the depleted batteries, with recovered metals exhibiting a metal assay falling within a predefined range of 98-99%.
2. The system as claimed in claim 1, wherein the batteries are selected from lithium-ion batteries and any combination thereof.
3. The system as claimed in claim 1, wherein the battery processor (102) comprises:
a battery dismantling and sorting unit (104-1) for dismantling and segregating individual battery cells based on an in-house protocol;
a discharging unit (104-2) for neutralizing remaining charge in the individual battery cells to prevent explosion during shredding;
a shredding unit (104-3) for extracting and breaking down the individual battery cells into small pieces; and
a separation unit (104-4) for separating the black mass from Cu-Al foil, plastic separator, casing materials, and any combination thereof.
4. The system as claimed in claim 1, wherein the black mass produced from the battery processor (102) is passed to a black mass recovery unit (106) that comprises silos, bag filters, and scrubbers for recovering the black mass from shredded cell materials, wherein the recovery of the black mass is within the range of 97-99%.
5. The system as claimed in claim 1, wherein the electrolyte solvents present in the depleted batteries are passed to an electrolyte recovery unit (108) comprising a closed-loop arrangement of heat exchanger and solvent collection columns for recovering the electrolyte solvents without leakage.
6. The system as claimed in claim 1, wherein the plastic processor (110) comprises:
a sorting unit (112-1) to segregate plastic, Al-Cu, steel casing, and iron; and
a separating unit (112-2) for separating plastic from Al-Cu, steel casing, and iron, and passing through a plastic recovery unit (120).
7. The system as claimed in claim 1, wherein the segregated steel and iron materials from the steel and iron processing unit (114) are passed through an iron recovery unit (122-1) and steel recovery unit (122-2) respectively, wherein the recovery of steel casing is within the range of 98-99%.
8. The system as claimed in claim 1, wherein the separated metals pertaining to Cu and Al from the metal separation unit (116) are transferred to respective metal processing units (118-1, 118-2), the metal processing units comprise a copper metal processing unit (118-1) and an aluminum metal processing unit (118-2), wherein the recovery of Cu and Al current collectors obtain the range of 95-98%.
9. The system as claimed in claim 1, wherein each metal processing unit is configured for processing metals selected from copper (Cu) and aluminum (Al), each metal processing unit comprises:
a washing unit configured to utilize high-pressure spray washing for cleaning metal surfaces to ensure absence of metal impurities;
a drying unit equipped with temperature and pressure controllers to facilitate thorough drying of the washed metals;
a briquetting unit incorporating a high-density metal chip briquetting machine to compress metal foil/chips into compact pallets using hydraulic pressure, thereby forming solid blocks with high density; and
a high-temperature furnace employed for melting high-density briquettes above respective melting points to yield metal ingots.
10. A method (200) for recycling metals from depleted batteries, the method comprising:
mechanically (202) shredding the depleted batteries using a battery processor (102) to produce black mass containing cathode and anode active material along with binders and recycle electrolyte solvents present in the depleted batteries;
employing (204), at a plastic processor (110), pneumatic conveying air classifier to segregate plastic from metals, steel casing, and iron;
incorporating (206), at a steel and iron processing unit, an eddy current separator with variable magnetic strength to segregate and recover steel and iron materials from the depleted batteries; and
utilizing a metal separation unit (116) comprising different sets of pulverizers and gravity separators for size classification and separation of the metals from the depleted batteries, with recovered metals exhibiting a metal assay falling within a predefined range of 98-99%.