Spent battery materials recycling method

Patent metadata

Field	Value
Publication number	US-2025323335-A1
Application number	US-202318869096-A
Country	US
Kind code	A1
Filing date	May 24, 2023
Priority date	May 25, 2022
Publication date	Oct 16, 2025
Grant date	—

Abstract

Disclosed herein is a method of recycling a spent battery material, the method comprising the steps of (a) providing a first reaction compartment fluidly connected to a cathode side of an electrolyser, (b) in a second reaction compartment, LiOH is added to precipitate the Co2+ to provide a filtered alkaline electrolyte solution which is supplied to a third reaction compartment when the Co2+ are substantially or are entirely removed from the filtered alkaline electrolyte solution by precipitation, and (c) in an initial state, the reaction compartment houses FePO4 and accepts the filtered alkaline electrolyte solution from the second reaction compartment, the reaction loops are continued until the Li+ ions are substantially or are entirely removed from the electrolyte. Also disclosed herein are an electrolytic device comprising an electrolyser, a first to third cathode tank, and an anode tank, and an electrolytic device comprising a first electrolyser, and a second electrolyser.

First claim

1 . A method of recycling a spent battery material, the method comprising the steps of:
(a) providing a first reaction compartment fluidly connected to a cathode side of an electrolyser that comprises a cathode compartment comprising a cathode, an anode compartment comprising an anode, and a cation exchange membrane separating the cathode and the anode compartments from one another, where an anode side of the electrolyser is set up to generate protons via an oxygen evolution reaction or a hydrogen oxidation reaction, where in an initial state the first reaction compartment comprises:
a solid spent battery material comprising LiCoO 2 and/or LiNi x Mn y Co z O 2 ; and
an acidic electrolyte comprising a first redox mediator capable of being reduced on the cathode, and
during a first reductive loop, the acidic electrolyte from the first reaction compartment is provided to the first cathode compartment to provide a reduced first redox mediator and the acidic electrolyte is returned to the first reaction compartment where the reduced redox mediator reacts with the solid spent battery material producing soluble Li + , Co 2+ and, when present, Ni 2+ and Mn 2+ ions, while the reduced first redox mediator is oxidised back to its original form and protons are supplied from the anode compartment via the cation exchange membrane,
during subsequent reductive loops, the acidic electrolyte from the first reaction compartment comprises the first redox mediator, and Li + , Co 2+ and, when present, Ni 2+ and Mn 2+ ions,
the subsequent reaction loops are continued until the Li, Co and, when present, Ni and Mn have been dissolved from the solid spent battery material, whereupon the acidic electrolyte comprising the first redox mediator, and Li + , Co 2+ and, when present, Ni 2+ and Mn 2+ ions is supplied to a second reaction compartment;
(b) in the second reaction compartment, the acidic electrolyte comprising the first redox mediator, and Li + , Co 2+ and, when present, Ni 2+ and Mn 2+ ions, LiOH is added to precipitate the Co 2+ and, when present, Ni 2+ and Mn 2+ ions to provide a filtered alkaline electrolyte solution comprising the first redox mediator, and Li + , which is supplied to a third reaction compartment when the Co 2+ and, when present, Ni 2+ and Mn 2+ ions are substantially or are entirely removed from the filtered alkaline electrolyte solution by precipitation; (c) in an initial state, the reaction compartment houses FePO 4 and accepts the filtered alkaline electrolyte solution from the second reaction compartment,
during a first reaction loop, the filtered alkaline electrolyte is supplied from the third reaction compartment to the cathode compartment to provide an electrolyte comprising a reduced first redox mediator and Li + ions and the electrolyte is returned to the third reaction compartment where the reduced redox mediator reacts with the FePO 4 producing LiFePO 4 and the reduced first redox mediator is oxidised back to its original form and protons are supplied from the anode compartment via the cation exchange membrane,
during subsequent reaction loops, the electrolyte from the third reaction compartment comprises the first redox mediator, and a reduced concentration of Li + ions,
the subsequent reaction loops are continued until the Li + ions are substantially or are entirely removed from the electrolyte, such that the electrolyte matches, or substantially matches, the acidic electrolyte of step (b), at which point the LiFePO 4 and any remaining FePO 4 are harvested.

2 . The method according to claim 1 , further comprising the steps of:
(i) providing a fourth reaction compartment fluidly connected to an anode side of an electrolyser that comprises an anode compartment comprising an anode, a cathode compartment comprising cathode, and a cation exchange membrane separating the cathode and the anode compartments from one another, where the cathode side of the electrolyser is set up to generate hydrogen gas and hydroxide ions via a hydrogen evolution reaction, the cathode compartment being fluidly connected to a storage tank, where in an initial state the fourth reaction compartment comprises:
the fourth reaction compartment the LiFePO 4 and any remaining FePO 4 harvested from step (d) of claim 1 and an electrolyte comprising a second redox mediator capable of being oxidised on the anode; and
the storage tank comprises water,
during a first reaction loop, the electrolyte from the fourth reaction compartment is provided to the anode compartment to provide an oxidised second redox mediator and the electrolyte is returned to the fourth reaction compartment where the oxidised redox mediator reacts with the LiFePO 4 to provide FePO 4 and Li + ions,
during subsequent reaction loops the electrolyte comprising the redox mediator and Li + ions is supplied to the anode compartment, where:
the redox mediator is converted into an oxidised redox mediator; and
at least some of the Li + ions are transported through the cation exchange membrane into the cathode compartment and hence to the storage tank,

the subsequent reaction loops are continued until the LiFePO 4 is substantially or entirely consumed and the storage tank comprises aqueous lithium hydroxide solution.

3 . The method according to claim 1 , wherein the first redox mediator has a redox potential lower than LiCoO 2 and/or LiNi x Mn y CO z O 2 , optionally wherein the first redox mediator has a redox potential of less than 0.4 V vs standard hydrogen electrode (SHE), such as from 0.05 to 0.39 V vs SHE, such as about 0.23 V vs SHE or about 0.31 V vs SHE.

4 . The method according to claim 3 , wherein the first redox mediator is one or both of Fe—SO 3 Li and AQDS-2NH 4 .

5 . The method according to claim 1 , wherein the first redox mediator has a concentration of from 1 to 100 mM in the acidic electrolyte, such as from 2 to 50 mM, such as about 40 mM or about 5 mM.

6 . The method according to claim 1 , wherein the acidic electrolyte is formed from water and an acidic compound, optionally wherein the acidic compound has a concentration of from 0.2 M to 5 M, such as from about 0.4 M to 3 M, further optionally wherein the acidic compound is sulphuric acid or acetic acid.

7 . The method according to claim 2 , wherein the second redox mediator is Li 3 [Fe(CN 6 )].

8 . The method according to claim 1 , wherein the method is operated as a closed loop.

9 . An electrolytic device comprising:
an electrolyser, which comprises a first cathode compartment comprising a cathode, a first anode compartment comprising an anode and a cation exchange membrane separating the first cathode and the first anode compartments from one another; a first to third cathode tank, where:
the first cathode tank is fluidly connected to at least the cathode compartment and to the second cathode tank;
the second cathode tank is fluidly connected to at least the first cathode tank and to the third cathode tank and can accept LiOH;
the third cathode tank is fluidly connected to at least the first cathode tank, the second cathode tank and the first cathode compartment; and
an anode tank fluidly connected to the first anode compartment, wherein: each of the first and third cathode tanks can be independently selected to be fluidly connected to the cathode compartment at any given time; the first cathode tank is configured to accept a spent battery material and an electrolyte and supply a liquid to the second cathode tank; the second cathode tank is configured to accept a liquid from the first cathode tank and to accept LiOH in solid and/or liquid form, and supply a liquid the third cathode tank; and the third cathode tank is configured to accept a liquid from the sec

Assignees

• Nat Univ Singapore

Inventors

• Wang Qing
• Zhi Yongfeng
• Huang Songpeng
• Zhang Feifei

Classifications

• H01M4/525

  of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy · CPC title

• H01M4/505

  of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy · CPC title

• C25B1/16

  Hydroxides (by simultaneous production of alkali metal hydroxides and chlorine, oxyacids or salts of chlorine C25B1/34) · CPC title

• C25B1/50 Primary

  Processes · CPC title

• C25B15/087

  Recycling of electrolyte to electrochemical cell · CPC title