Energy reclamation and carbon-neutral system for ultra-efficient EV battery recycling

Patent metadata

Field	Value
Publication number	US-11827991-B1
Application number	US-202217948030-A
Country	US
Kind code	B1
Filing date	Sep 19, 2022
Priority date	Sep 19, 2022
Publication date	Nov 28, 2023
Grant date	Nov 28, 2023

Abstract

The presently disclosed concepts relate to ultra-efficient EV battery recycling systems. Alkali metal extraction (and in particular lithium extraction) is accomplished using a solid electrolyte membrane. By using a solid electrolyte embedded in a matrix, alkali metals, in particular lithium can be (energy-wise) efficiently separated from feed solutions. The energy used to initially extract lithium from a feed solution is stored as electrochemical energy, which electrochemical energy is reclaimed in subsequent extraction processing steps. This energy storage and energy reclamation is performed in continuous ultra-efficient ongoing cycles. Since irrecoverable energy losses incurred in each cycle are limited to negligible amounts of joule heating of the system components and feed solution, the system can be sustainably powered using locally-generated renewable energy.

First claim

What is claimed is:

1. A method for reclaiming energy, the method comprising:
transporting lithium ions from a feed solution to a first electrode through a first membrane comprising a first solid electrolyte embedded in a first matrix,
wherein:
the transporting of the lithium ions from the feed solution to the first electrode requires an input of energy,
the first solid electrolyte is configured to extract the lithium ions, and
the feed solution is a separate input source from a first electrolyte solution associated with the first electrode;

transporting second ions from a second electrode to the feed solution through a second membrane comprising a second solid electrolyte embedded in a second matrix, wherein the transporting of the second ions from the second electrode to the feed solution coincides with the transporting of the lithium ions from the feed solution to the first electrode; and
transporting the lithium ions from the first electrode to a second electrolyte solution through the first membrane, wherein the transporting of the lithium ions from the first electrode to the second electrolyte solution recovers at least a portion of the input of energy.

2. The method of claim 1 , wherein the input of energy is stored as electrochemical energy of the lithium ions stored in the first electrode, and recovering the at least a portion of the input of energy reduces a carbon footprint of a manufacturing facility.

3. The method of claim 1 , wherein the feed solution is based on at least one of lithium minerals, lithium-containing brines, recycled lithium batteries, or seawater.

4. The method of claim 1 , wherein the voltage drop is proportional to a thickness of at least one of the first membrane or the second membrane, or to the ohmic resistance of at least one of the first membrane or the second membrane.

5. The method of claim 1 , wherein each of the lithium ions passes through a single particle of the first solid electrolyte of the first membrane.

6. The method of claim 1 , wherein:
the first membrane and the second membrane are each water impermeable;
the first membrane is ion-selective for the lithium ions;
second membrane is ion-selective for the second ions; and
the second ions includes at least one of sodium, potassium, or hydrogen.

7. The method of claim 1 , wherein transporting the lithium ions from the first electrode into the second electrolyte solution through the first solid electrolyte coincides with an uptake of the second ions from the second electrolyte solution into the second electrode through the second solid electrolyte.

8. The method of claim 1 , wherein the first solid electrolyte is at least one of: LATP, LZP, LAGP, LiSICON, or LTO; and the second solid electrolyte is at least one of NaSICON or K2Fe4O7.

9. The method of claim 1 , wherein the first membrane serves as an electrical buffer between the first electrode and at least one of the feed solution or the second electrolyte solution; and the second membrane serves as an electrical buffer between the second electrode and at least one of the feed solution or the second electrolyte solution.

10. The method of claim 1 , wherein at least one of:
a diameter of the first solid electrolyte is at least 10 μm (microns);
a material for the first matrix and the second matrix is the same; or
a material for the first matrix and the second matrix is different.

11. The method of claim 1 , wherein at least one of the first electrode or the second electrode comprises a third electrolyte solution, a binder, active material particles, and a current collector.

12. The method of claim 11 , wherein the third electrolyte solution is liquid, and one or more sides of the first electrode and the second electrode are lined by an adhesive configured to prevent the feed solution containing the lithium ions from reaching the active material particles of the either of the first electrode or the second electrode.

13. The method of claim 1 , wherein a structure of the matrix is densely crosslinked and hydrophobic.

14. The method of claim 1 , wherein the molecules of the matrix covalently bond with particles of the first solid electrolyte.

15. The method of claim 1 , wherein the first membrane is water impermeable, and the first solid electrolyte is ion-selective for the lithium ions.

16. The method of claim 1 , wherein the feed solution is sea water.

17. The method of claim 1 , wherein the feed solution is previously used and spent batteries.

18. The method of claim 1 , wherein the lithium ions pass through a single particle of the first solid electrolyte of the first membrane.

Assignees

• Lyten Inc

Inventors

• Baucom Jesse
• Kolli Sanjeev

Classifications

• C25C1/02 Primary

  of light metals · CPC title

• C25C7/02 Primary

  Electrodes (consumable anodes for the refining the metals C25C1/00 - C25C5/00); Connections thereof · CPC title

• H01M10/54

  Reclaiming serviceable parts of waste accumulators · CPC title