safety in electric vehicle and battery recycling · 2019. 9. 17. · eol lib: dangerous good...
TRANSCRIPT
#LCV2019 @LCV_Event
Safety in Electric Vehicle and Battery
RecyclingDr Anwar Sattar
Lead Engineer – WMG, The University of Warwick
Session Sponsor:
Safety in Electric Vehicle and Battery Recycling
04/09/2019LCV Event, MillbrookAnwar Sattar (Lead Engineer, WMG)[email protected]
©WMG 2019
Need for Battery Recycling
Safe processing
©WMG 2019
EV numbers are growing2019: >220,000 plug in vehicles on road in the UK
000’s more hybrids
2030: 3-10million vehicles on road in the UK
000’s tonnes of EoL batteries
0
10000
20000
30000
40000
50000
60000
70000
2011 2012 2013 2014 2015 2016 2017 2018
Plug in Vehicle Sales
BEV PHEV
Source: SMMT Source: National Grid
Current Situation
©WMG 2019
No LIB recycling process in the UKPacks need shipping to mainland Europe
EoL LIB: dangerous good
Difficult to ship
Expensive process
EoL pack
Dealership
Specialist company
Discharge and dismantle
Package Shipped to recycler
Vehicle Recycling
Conventional Electric
Storage
Airbag inflation
Battery removal
Vehicle recycling
Storage
Battery removal
Airbag inflation
Vehicle recycling
Battery storage
Battery diagnosis
Battery transport
Battery recycling
Depollution Depollution
ELV Directive85% recycle/reuse
10% energy recovery
Battery Directive50% recycling
©WMG 2019
ELV Directive
Battery Removal
©WMG 2019
Pre-removalIdentification
Badges, HV cables, etc
Process
Research vehicle
IDIS
Vehicle condition
Dry, well lit location
Shut down vehicle
Lock key
De-energise vehicle
Place signs
Remove service disconnectswitch (SDS, MSD)
Safety EquipmentLinesman gloves (class 0)
Rubber mat
Safety hook
Safety specs
Hard hat
Insulated tools
Hydraulic lifting gear
Multi-meter
Battery Storage
Chemistry SegregationKeep Li-ion away from Pb-acid, NiMH, etc
Efficient space utilisation
Correct packaging required
Storage building requirements
Cool/dry
Fire suppression
Sensors
©WMG 2019
Battery Recycling Process
1. Pre-treatment2. Processing +
electrolyte treatment
3. Material separation
4. Hydrometallurgical Recovery
Discharging
Dismantling
Pyrolysis
Freezing
Wet shredding
Pyrometallurgical
Inert shredding
Controlled atm’ shredding
Dry separation
Wet separation
Magnetic separation
Screening
Cathode leaching
Solvent extraction
Alloy leaching
Precipitation
©WMG 2019
Battery Abuse
©WMG 2019
1.Battery Pack Discharge and Dismantling
DischargingSoC reduced to ~0%
Li → cathode: stable
Less sparking
©WMG 2019
HazardsHigh V, A
Fully charged >350V
95% discharge; ~300V
1.Pyrolysis, Freezing
©WMG 2019
PyrolysisThermal degradation (organic matter)
Inert atmosphere
200-500oC
Destroys electrolyte
Cells safe to process
Easier downstream separation
Grandjean et al. Journal of Energy Storage 21 (2019) 202–215
F. Diaz et al./Waste Management 84 (2019) 102–111
Liquid nitrogen-195oC
Electrolyte frozen
No Li+ diffusion
Li + electrolyte require treatment
High temperature processingCell material used for energy
Electrolyte
Plastic
Graphite
Low recycling efficiency
Only recovers Ni, Cu, Co, Fe
Li, Al, Mn end up in slag
2. Pyrometallurgical Processing
©WMG 2019
HazardsBattery explosions
Toxic gases produced
2. Shredding
Safe processing
©WMG 2019
Types of ShreddingShredding in inert atmosphere
N2 or vacuum
No O2: no combustion
Shredding in controlled atmosphere
CO2
2Li + 2CO2 → Li2CO3 + CO
Wet Shredding
Water + chemical
Water: fire suppressant
Chemical: reaction suppressant
3. Material Separation
Module compositionModule casing
Wires
Busbars
Circuit boards
Cells
Electrolyte
Separators
Cathode
Anode
Tabs
©WMG 2019
3. Electrolyte Recovery
Duesenfeld Process, Electrolyte recovery
Electrolyte composition
Linear carbonate
Cyclic carbonate
LiPF6
Various additives
Solvent extraction
Selective extraction of components
Higher efficiencies
Energy intensive
Flammable solvents
Supercritical CO2 extraction
Recovers all electrolyte
Low temperature process
High pressure process (71 atm)
Asphyxiation
Vacuum distillation
Low pressure
Reduces boiling point
Vapour cooled
Further separation required
LiPF6 not recovered
©WMG 2019
3. Density Separation
Dry separation
Difference in density
Air based
Zigzag separator
Air table
Hazards
Dust
HF formation
Wet separation
Difference in density
Water based
Hydrocyclone
Water table
Water separator
Salt based (sink float)
HazardsHF formation
©WMG 2019
Cathode powder Acid leach Solvent extraction Precipitation
4.Hydrometallurgical Metal Recovery
©WMG 2019
Recycling Efficiency
©WMG 2019
Company Capacity (t/y) Type Process Efficiency (cells)
Umicore 7000 Full recycler PyrometallurgicalHydrometallurgical
>50%
SNAM 300 (?) Shredder Pyrolysis, shredding, separation Up to 80% (?)
Accurec 1500-2000 shredder Pyrolysis, shredding, separation, pyrometallurgical
~60%(70% if slag used)
Duesenfeld 3000 Full recycler Shredding, electrolyte recover, material sep, hydrometallurgical
85%
Value per Pack
©WMG 2019
Pack component % Mass Kg per pack Value ($/kg) Value per pack $
Cells 60% 142 30.5* 15.8** 4326* 2241**
Pack Casing 30% 71 0.45 32Wiring 4% 9.5 6 26Electronic components 1.5% 2.4a 1.1b 6a 2b 14.4a 2.2b
Cooling tubes, casing
parts
1.5% 3.5 0 0
Busbars 1.5% 3.5 6 21Screws, metal parts 1% 2.4 0.45 1
Rubber, tape, etc 0.5% 1.1 0 0
Total 100% 236.5 4420* 2338**
* Co, Ni containing cells
** LMO cells
a) Copper price, b) Scrap circuit board price
Conclusions
Safe processing
©WMG 2019
Safety is criticalHazards
Electrical
Flammable
Explosive
Toxic
Carcinogenic
Corrosive
Appropriate processes, engineering controls and PPE minimises risk
