from battery-to-precursor - recycling of lithium-ion batteries
TRANSCRIPT
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 1
From Battery to Precursor and back again - Recycling of Lithium-Ion Batteries -
Christian Hanisch, Lion Engineering GmbH, [email protected]
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 2
Loss of ressources
Energy consuming Recycling fees
Impurities from recycling interfere with
re-synthesis of new battery active
materials
Recycling of Lithium-Ion Batteries - Problems
transportation of hazardous waste > 500 €/t
Disposal: ~ 1.000 €/t
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 3
Composition of a traction battery
Battery system Battery cells Electrodes Current collector
+ Active material
Reference: TU Braunschweig
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 4
Battery Cell Composition
Separator 4% Rod
2% Case 11%
Lithium 2%
Cobalt 7%
Nickel 6%
Manganese 6%
Oxygen 11%
Al Foil 5%
Anode Coating 19%
Cu Foil 11%
Electrolyte 16%
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 5
World market prices – 06.04.2016
1.498
4.775
22.800
8.270
1.630
Aluminum Copper Cobalt Nickel Manganese
Pri
ce in
USD
per
to
n
Prospective active materials: More and more spinel and olivine structures (e.g. LFP) without cobalt and nickel
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 6
Unit operations of battery recycling
Mech. treatment Hydrometallurgy Pyrometallurgy
Shredding
Classifying
(e.g. sieving, separating)
Sorting
(e.g. magnetic separation)
Smelting of the
whole battery
cells
electrodes
active materials
Recovery of
transition metals Co,
Ni
Chemical processes
Leaching
Extraction
Crystallization
Precipitation
Recovery of
pure metals from
Active materials
Slag
Deactivation
Thermal
pretreatment
Discharge
Freezing of the
electrolyte
Reference: Recycling of Lithium-Ion Batteries Christian Hanisch, Jan Diekmann, Alexander Stieger, Wolfgang Haselrieder, Arno Kwade Handbook of Clean Energy Systems - Volume 5 Energy Storage, 2015 edited by Jinyue Yan, Luisa F. Cabeza, Ramteen Sioshansi, 01/2015: chapter 27: pages 2865-2888; John Wiley & Sons, Ltd.., ISBN: 978-1-118-38858-7
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 7
Process routes
Li
Co, Ni
Mechanical treatment Hydrometallurgy
Casing, etc.
Cu, Al
Battery / Battery cells
Pyrometallurgy
Co, Ni, Mn
Cu
Reference : Recycling of Lithium-Ion Batteries
Deactivation
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 8
State of the art: Technically possible:
on battery cell level
Green: material recycling
Red: other recycling or disposal
Recycling Efficiency
Separator 4%
Rod 2%
Case 11%
Lithium 2%
Cobalt 7%
Nickel 6%
Manganese 6%
Oxygen 11%
Al Foil 5%
Anode Coating 19%
Cu Foil 11%
Electrolyte 16%
Separator 4%
Rod 2%
Case 11%
Lithium 2%
Cobalt 7%
Nickel 6%
Manganese 6%
Oxygen 11%
Al Foil 5%
Anode Coating
19%
Cu Foil 11%
Electrolyte 16%
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 9
Basic structure of the process chain
Casing,
BMU, wires,
busbars,
screws
Disassembly
battery system Disassembly
battery modules
Wires,
busbars,
screws…
cooling units
Battery system
Discharge/
Deactivation
Electric
energy
Cell
processing
Material
processing
Electrolyte,
copper/aluminum
Transition metals
Lithiumsalt with
high purity
Reference: TU Braunschweig Further information: Recycling of Lithium-Ion Batteries
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 10
Example: Cell shredding and sorting
Pre shredding
Magnetic separation
Cross flow sifter
Pneumatic table
Cells / Modules
Electrode
fragments
Separator foil
Heavy fraction:
Steel-/Al-Casing
Fe
Reference: TU Braunschweig
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 11
Air Classification and Sieving
Zigzag-Classifier
Air jet
Heavy fraction
Light fraction
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 12
Separation results after sifting and sieving
Reference: TU Braunschweig and Lion Engineering GmbH
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 13
Separation results after sifting and sieving
Reference: TU Braunschweig and Lion Engineering GmbH
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 14
Hydrometallurgical process
Leaching / Extraction of active material
Purification through:
- Crystallisation
- Ion-exchange
Salt separation by
electrochemical processes
LiOH / Li2CO3
Co
, N
i, M
n-S
ol.
Li-brin
e
Precipitation
Metal oxide particles
New active materials
Calcination
Reference: TU Braunschweig
Referenz
LNCMO V21
LNCMO V5-Z
Special thanks to H.C. Starck and Rockwood Lithium
Further information:
LithoRec project report,
2011
and
Effect of Impurities
Caused by a Recycling
Process on the
Electrochemical
Performance of
Li[Ni0.33Co0.33Mn0.33]O2
S. Krueger et al.,
Journal of Electroanalytical
Chemistry 07/2014; 726:
91-96.
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 15
Pilot Plant LithoRec II • Realized in Research Project
LithoRec II funded by the Federal Ministry for the Environment with project partners TU Braunschweig, Volkswagen
• Discharging, Dismantling, Crushing, Electrolyte Removal, Sifting and Sieving
• Material Recycling of 75% of a BEV system
• Lion Engineering GmbH tested its patent pending process
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 16
1 metric ton LIB-System
Input and Output
Process Costs vs. Sales Value
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 17
Recycling of Production Scraps/Rejects
0 100 200 300 400 500
0
20
40
60
80
100
120
140
Sp
ecific
Ca
pa
city [m
Ah
/g]
Cycle [-]
Material / Separation method
Reference
Rejects / Mechanical
Rejects / Chemical
Electrochemical Cycling of Directly Recoated Reject Materials
Charge / Discharge Rate 3C/3C
25 cm² Pouch Cell, C = 44 mAh, T = 21 °C
(Re-)Coating
Solvent
Dispersing
A
n
t
r
i
e
b
ω
Separated
Coating
Reference: TU Braunschweig and Lion Engineering GmbH
Further information: In-Production Recycling of Active Materials from Lithium-Ion Battery Scraps in ECS Transactions 64(22): 131-145 · April 2015
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 18
Conclusion
Metallurgical recycling of spent batteries is feasible
to regain Co and Ni
Future battery materials challenge battery
recyclers even more economically
Increasing of recycling yield possible by
Combination of different unit operations
Challenges:
Safety
Purity
Process costs
Further information: Recycling of Lithium-Ion Batteries & Recycling of Lithium-Ion Batteries: A Novel Method to Separate Coating and Foil of Electrodes
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 19
To Do: Further R&D
Tasks in proposed process chain:
Providing Batteries
Extraction of battery active material
Re-synthesizing battery active material
Equipping EV with recycled battery material
Analytics, LCA, Battery Test Cells
Join LinkedIn Group Lithium-Ion Battery Recycling
Christian Hanisch, Recycling of Lithium-Ion Batteries, April 7, 2016, Slide 20
… especially from both LithoRec projects and at
BLB and TU Braunschweig.
Thanks to the Federal Ministry of the
Environment, Nature Conservation, Building and
Nuclear Safety
Further questions?
Christian Hanisch
Thank you…. and Thanks to all our partners…