Energy reclamation and carbon-neutral system for critical mineral extraction

Patent metadata

Field	Value
Publication number	US-12148902-B2
Application number	US-202318122621-A
Country	US
Kind code	B2
Filing date	Mar 16, 2023
Priority date	Mar 16, 2023
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

The presently disclosed concepts relate to green battery recycling systems and critical mineral reclamation and refinement. Alkali metal extraction (and in particular lithium extraction) is accomplished using a solid electrolyte membrane in combination with electrodes in a redox configuration. The energy used to initially extract lithium from a feed solution is stored as electrochemical energy, which electrochemical energy is reclaimed in subsequent reclamation processing steps. This reclamation may further allow for lithium to be converted to lithium carbonate or lithium hydroxide, or purified to a minimum purity of 99.9% lithium by mass. These extraction and reclamation steps may 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, which in turn, provides for a green and sustainable solution for lithium recycling.

First claim

What is claimed is:

1. A method for reclamation of lithium mineral, the method comprising:
driving migration of lithium ions using a current passing from an anode to a cathode, wherein the current is driven by a redox configured flow of ions associated with the anode and the cathode;
extracting, using an extraction reaction, the lithium ions from a first solution into a second solution through an ion-selective solid electrolyte membrane, wherein the ion-selective solid electrolyte membrane is configured to selectively allow the lithium ions to pass;
providing an input of electrochemical energy for the extraction; and
after the extraction, causing a reclamation of the lithium ions, wherein the reclamation comprises using a reclamation reaction comprising:
a) converting the lithium ions to lithium carbonate;
b) converting the lithium ions to lithium hydroxide;
c) transporting the lithium ions from the second solution via the ion-selective solid electrolyte membrane; or
any combination of a), b), and/or c); and

wherein the reclamation recovers at least a portion of the input of electrochemical energy;
wherein extracting the lithium ions from the first solution to the second solution coincides with an uptake of ions of a second alkali metal from a third solution to the first solution; and
wherein the third solution is separated from the first solution by a second ion-selective solid electrolyte membrane.

2. The method of claim 1 , wherein the reclamation includes purifying the lithium ions to a minimum of 99.9% lithium by mass.

3. The method of claim 1 , wherein the input of electrochemical energy is stored as electrochemical energy of the lithium ions.

4. The method of claim 1 , wherein recovering the at least a portion of the input of electrochemical energy reduces a carbon footprint of a manufacturing facility.

5. The method of claim 1 , wherein the first solution comprises at least one of: lithium minerals, lithium-containing brines, recycled lithium batteries, geothermal brines, salar brines, or seawater.

6. The method of claim 1 , wherein the ion-selective solid electrolyte membrane is water impermeable.

7. The method of claim 1 , wherein the extraction and the reclamation facilitate recycling of lithium ions, which in turn reduces a carbon footprint of a manufacturing facility and allows for sustainable reuse of lithium batteries.

8. A method for reclamation of lithium mineral, the method comprising:
driving migration of lithium ions using a current passing from an anode to cathode, wherein the current is driven by a redox configured flow of ions associated with the anode and the cathode;
extracting the lithium ions, using an extraction reaction, from a first solution into a second solution through an ion-selective solid electrolyte membrane, wherein the extraction reaction comprises replacing the lithium ions with sodium ions, and wherein the ion-selective solid electrolyte membrane is configured to selectively allow the lithium ions to pass;
providing an input of electrochemical energy for the extraction; and
after the extraction, causing a reclamation of the lithium ions, using a reclamation reaction comprising:
a) converting the lithium ions to lithium carbonate;
b) converting the lithium ions to lithium hydroxide;
c) transporting the lithium ions from the second solution via the ion-selective solid electrolyte membrane; or
any combination of a), b), and/or c); and

wherein the reclamation recovers at least a portion of the input of electrochemical energy and the reclamation includes:
replacing the first solution with a third solution;
transporting the lithium ions from the second solution to the third solution via the ion-selective solid electrolyte membrane; and
removing ions of a second alkali metal from the third solution to a fourth solution via a second ion-selective solid electrolyte membrane, wherein the transporting of the ions of the second alkali metal from the third solution to the fourth solution coincides with the transporting of the lithium ions from the second solution to the third solution, wherein the fourth solution is separated from the third solution via the second ion-selective solid electrolyte membrane.

9. A method for reclamation of lithium mineral, the method comprising:
driving migration of lithium ions using a current passing from an anode to cathode, wherein the current is driven by a redox configured flow of ions associated with the anode and the cathode;
extracting the lithium ions, using an extraction reaction, from a first solution into a second solution through an ion-selective solid electrolyte membrane, wherein the extraction reaction comprises replacing the lithium ions with sodium ions, and wherein the ion-selective solid electrolyte membrane is configured to selectively allow the lithium ions to pass;
providing an input of electrochemical energy for the extraction; and
after the extraction, causing a reclamation of the lithium ions, wherein the reclamation comprises using a reclamation reaction comprising:
a) converting the lithium ions to lithium carbonate;
b) converting the lithium ions to lithium hydroxide;
c) transporting the lithium ions from the second solution via the ion-selective solid electrolyte membrane; or
any combination of a), b), and/or c); and any combination of a), b), and/or c); and

wherein the reclamation recovers at least a portion of the input of electrochemical energy;
wherein the extraction and reclamation are performed, at least in part, using a lithium module comprising:
the ion-selective solid electrolyte membrane;
the second solution, wherein the second solution includes a lithium electrolyte; and
an active material in direct contact with the second solution; and

wherein the extraction and reclamation are further performed, at least in part, using a sodium module comprising:
a second ion-selective solid electrolyte membrane, wherein the second ion-selective solid electrolyte membrane is sodium selective;
a third solution, wherein the third solution includes a sodium electrolyte; and
a second active material in direct contact with the third solution.

Assignees

• Lyten Inc

Inventors

• Baucom Jesse
• Kolli Sanjeev

Classifications

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• B01D69/02

  characterised by their properties · CPC title

• C22B26/12

  Obtaining lithium · CPC title

• C22B3/46

  by substitution, e.g. by cementation · CPC title

• B01D61/44

  Ion-selective electrodialysis · CPC title