LITHIUM-ION BATTERY CELL RECYCLING PROCESS
A method of recycling a lithium-ion battery, having a lithium-based cathode material deposited on a metallic cathode collector and an anode material deposited on a metallic anode collector, includes the steps of isolating an individual battery cell from a lithium-ion battery, and mechanically segmenting the battery cell into a plurality of pieces. The resulting segments are heated in an inert, dry atmosphere to a temperature below the melting point of the metallic components of the cell. Once cooled, the lithium-based cathode material is separated from the cathode collector in a first separation operation. A subsequent second separation operation separates the cathode collector from the anode collector.
1 . A method of recycling a lithium-ion battery cell having a lithium-based cathode material deposited on a metallic cathode collector and an anode material deposited on a metallic anode collector, comprising the steps of:
mechanically segmenting the battery cell into a plurality of pieces;
controlled heating of the plurality of pieces in an inert atmosphere;
separating the lithium-based cathode material from the metallic cathode collector; and
separating the cathode collector from the anode collector.
2 . The method of claim 1 , wherein the plurality of pieces comprise pieces of mixed copper foil coated with a carbon anode material attached immediately adjacent to aluminum foil coated with a lithium cathode material.
3 . The method of claim 1 , wherein the step of separating the cathode collector from the anode collector occurs after the step of separating the lithium-based cathode material from the metallic cathode collector.
4 . The method of claim 1 , further comprising the step of controlled cooling of the plurality of pieces after the step of controlled heating.
5 . The method of claim 1 , wherein the step of separating the cathode collector from the anode collector is performed by an eddy current separator.
6 . The method of claim 1 , wherein the step of controlled heating of the plurality of pieces in an inert atmosphere is performed by a pyrolysis reactor.
7 . The method of claim 6 , wherein the step of controlled heating of the plurality of pieces with a pyrolysis reactor comprises heating the pieces to a temperature of less than 660° C.
8 . The method of claim 7 , wherein the inert atmosphere comprises a dry atmosphere without the presence of water or steam.
9 . The method of claim 8 , further comprising the steps of, after mechanically segmenting the battery cell into a plurality of pieces and before the controlled heating of the plurality of pieces in an inert atmosphere with a pyrolysis reactor:
heating the plurality of pieces in an oven; and
removing a polymer separator layer from between the cathode collector and the anode collector.
10 . The method of claim 9 , wherein the step of heating the plurality of pieces in an oven includes heating the pieces to a temperature of approximately 100° C.
11 . The method of claim 1 , wherein the step of separating the lithium-based cathode material from the metallic cathode collector includes subjecting the plurality of pieces to a vibrating and/or shaking mechanical separation operation.
12 . The method of claim 1 , further comprising the step of isolating the battery cell from a lithium-ion battery comprising a plurality of battery cells.
13 . A system for recycling lithium-ion batteries, comprising:
a cutting device for segmenting a lithium-ion battery cell into pieces;
a heat-generating reactor operating in an inert, dry atmosphere in which the pieces of the cell are heated;
a first separator for removing lithium-based cathode material from a metallic cathode collector of the pieces of the battery cell; and
a second separator for separating the metallic cathode collector from a metallic anode collector after the lithium-based cathode material has been removed from the metallic cathode collector.
14 . The system of claim 13 , wherein the first separator is a mechanical separator for shaking and/or vibrating the pieces of the battery cell.
15 . The system of claim 13 , wherein the second separator is an eddy current separator.
16 . The system of claim 13 , further comprising an oven for heating the pieces of the cell prior to their heating in the heat-generating reactor.
17 . The system of claim 16 , further comprising an air jet separator for removing a separation material from the metallic collector after heating in the oven.
18 . The system of claim 13 , further comprising a cooling chamber for cooling the pieces of the cell after they are heated in the heat-generating reactor.