Battery recycling

Patent metadata

Field	Value
Publication number	US-2025253426-A1
Application number	US-202418886523-A
Country	US
Kind code	A1
Filing date	Sep 16, 2024
Priority date	May 7, 2020
Publication date	Aug 7, 2025
Grant date	—

Abstract

Various embodiments relate to several processes that may recover commodity chemicals from an alkaline metal-air battery. In various embodiments, while the cell is operating, various side products and waste streams may be collected and processed to regain use or additional value. Various embodiments also include processes to be performed after the cell has been disassembled, and each of its electrodes have been separated such as not to be an electrical hazard. The alkaline metal battery recycling processes described herein may provide multiple forms of commodity iron, high purity transition metal ores, fluoropolymer dispersions, various carbons, commodity chemicals, and catalyst dispersions.

First claim

1 . (canceled)

2 . A method of operating an electrochemical system, the method comprising:
operating the electrochemical system; capturing a rechargeable alkaline manganese (RAM) cathode decay product from the electrochemical system; and using the RAM cathode decay product as an oxygen reduction reaction (ORR) catalyst in an air electrode of the electrochemical system.

3 . The method of claim 2 , wherein the RAM decay product includes Mn 3 O 4 .

4 . The method of claim 2 , wherein the ORR catalyst is a spinel-based catalyst, and using the RAM cathode decay product as the ORR catalyst includes using the RAM cathode decay product as a starting material for synthesizing the spinel-based catalyst.

5 . A method of operating an electrochemical system, the method comprising:
operating the electrochemical system to store and discharge energy; capturing a waste stream generated by the electrochemical system during operation in one or both of storing or discharging energy; and using the waste stream for water capture, hydrogen capture, heat energy capture, regeneration of CO 2 scrubbing agents, and/or electrolyte recycling.

6 . The method of claim 5 , further comprising removing additional value material from the waste stream, wherein the additional value material includes commodity iron, high purity transition metal ores, fluoropolymer dispersions, carbon, and/or a catalyst dispersion.

7 . A method of battery recycling, the method comprising:
decommissioning an electrochemical system including a gas diffusion electrode; separating a current collector from a carbon active layer of the gas diffusion electrode; and restoring hydrophobicity of carbon powder of the carbon active layer of the gas diffusion electrode.

8 . The method of claim 7 , wherein separating the current collector from the carbon active layer of the gas diffusion electrode includes mechanically treating the gas diffusion electrode.

9 . The method of claim 7 , wherein restoring the hydrophobicity of the carbon powder of the carbon active layer includes reducing surface species on the carbon powder.

10 . The method of claim 7 , wherein restoring the hydrophobicity of the carbon powder includes separating out sizes of particles from the carbon powder.

11 . The method of claim 7 , further comprising separating a gas diffusion layer from the gas diffusion electrode and returning a polymer of the gas diffusion layer to a crystalline form.

Assignees

• Form Energy Inc

Inventors

• Perkins Nicholas Reed
• Caruso Isabella
• Mumma Rachel Elizabeth
• Tran Anthony
• Chakraborty Rupak
• Via Matthew Edward
• Newhouse Jocelyn Marie
• Milshtein Jarrod David
• Su Liang
• Gibson Michael Andrew
• Smith Danielle Cassidy
• Woodford William Henry
• Kharey Amelie Nina

Classifications

• C22B7/006

  Wet processes · CPC title

• C22B3/16

  in organic solutions · CPC title

• C22B3/12

  in inorganic alkaline solutions · CPC title

• C22B3/04

  by leaching (C22B3/18 takes precedence) · CPC title

• C22B1/02

  Roasting processes (C22B1/16 takes precedence) · CPC title