WO2026032979A1 - Récupération de composants à partir de matériaux riches en carbone - Google Patents

Récupération de composants à partir de matériaux riches en carbone

Info

Publication number
WO2026032979A1
WO2026032979A1 PCT/EP2025/072507 EP2025072507W WO2026032979A1 WO 2026032979 A1 WO2026032979 A1 WO 2026032979A1 EP 2025072507 W EP2025072507 W EP 2025072507W WO 2026032979 A1 WO2026032979 A1 WO 2026032979A1
Authority
WO
WIPO (PCT)
Prior art keywords
permeate
graphite
solution
mixture
residue
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2025/072507
Other languages
English (en)
Inventor
Atit Bhargava
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
True 2 Materials Pte Ltd
Original Assignee
True 2 Materials Pte Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by True 2 Materials Pte Ltd filed Critical True 2 Materials Pte Ltd
Publication of WO2026032979A1 publication Critical patent/WO2026032979A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00Carbon; Compounds thereof
    • C01B32/20Graphite
    • C01B32/21After-treatment
    • C01B32/215Purification; Recovery or purification of graphite formed in iron making, e.g. kish graphite
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09CTREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK  ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
    • C09C1/00Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
    • C09C1/44Carbon
    • C09C1/46Graphite
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B1/00Preliminary treatment of ores or scrap
    • C22B1/005Preliminary treatment of scrap
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B23/00Obtaining nickel or cobalt
    • C22B23/04Obtaining nickel or cobalt by wet processes
    • C22B23/0407Leaching processes
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B23/00Obtaining nickel or cobalt
    • C22B23/04Obtaining nickel or cobalt by wet processes
    • C22B23/0407Leaching processes
    • C22B23/0415Leaching processes with acids or salt solutions except ammonium salts solutions
    • C22B23/043Sulfurated acids or salts thereof
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B26/00Obtaining alkali, alkaline earth metals or magnesium
    • C22B26/10Obtaining alkali metals
    • C22B26/12Obtaining lithium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/04Extraction of metal compounds from ores or concentrates by wet processes by leaching
    • C22B3/06Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions, e.g. with acids generated in situ; in inorganic salt solutions other than ammonium salt solutions
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/04Extraction of metal compounds from ores or concentrates by wet processes by leaching
    • C22B3/06Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions, e.g. with acids generated in situ; in inorganic salt solutions other than ammonium salt solutions
    • C22B3/08Sulfuric acid, other sulfurated acids or salts thereof
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B3/00Extraction of metal compounds from ores or concentrates by wet processes
    • C22B3/20Treatment or purification of solutions, e.g. obtained by leaching
    • C22B3/44Treatment or purification of solutions, e.g. obtained by leaching by chemical processes
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B47/00Obtaining manganese
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B59/00Obtaining rare earth metals
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/006Wet processes
    • C22B7/007Wet processes by acid leaching
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/009General processes for recovering metals or metallic compounds from spent catalysts
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00Secondary cells; Manufacture thereof
    • H01M10/54Reclaiming serviceable parts of waste accumulators
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/84Recycling of batteries or fuel cells

Definitions

  • the present invention relates to a process to recover components, including graphite from carbon-rich or graphite-containing materials, for example, from products such as batteries and petroleum refining by-products.
  • the process is also able to recover all other components including metals, non-metals, electrolytes and binders.
  • the process comprises (a) recovery of binders and electrolytes (b) recovery of graphite and (c) recovery of all metals including Lithium.
  • the process does so in a safe manner, and in a closed loop, introducing no sulphates or additional metal ions and allowing for complete recovery of constituents in a closed loop process.
  • Batteries are an essential component of vehicles such as trucks, ships and cars; household energy storage units; industrial energy units and commercial buildings energy units. As their application increase and the number of batteries in the world rises, so will the expired, defaulted and damaged batteries. There is therefore a desire for methods for recovering materials from these batteries.
  • black mass as referring to shredded material from solid state batteries.
  • cea hal science/cea- 03321722/document discusses electrochemical approaches for the recovery of metals from electronic. https://www.hazenresearch.com/capabilities/hvdrometallurciv/Drecipitation looks at hydrometallurgical methods for recovering metals through precipitation.
  • a method for the recovery of graphite from graphite-containing materials comprising:
  • the invention involves a number of steps which may be performed sequentially, concurrently or simultaneously.
  • the process may be continuous or batch.
  • the present inventors have provided a safe process for the recovery of materials from shredded solid-state battery material, also known as “black mass” and all graphite containing derivatives.
  • the method allows for recovery of a range of materials including metals, non- metals, binders, electrolytes and graphite. Recovery of these materials means that they can be reused to make fresh products and address concerns.
  • the process described herein may expanded to all graphite containing or metal containing products such as solar panels, petroleum derivatives, filters and polymer membranes. These products include coke or carbonaceous products of charring and calcining organic materials.
  • the powdered or granulated graphite-containing material comprises or consist of one or more of:
  • the powdered or granulated graphite-containing material comprises or consist of shredded solid-state battery material.
  • the shredded solid state battery material is obtained from shredding de-cased solid state batteries.
  • the first permeate comprises electrolytes and/or binders.
  • Batteries generally consist of a casing surrounding and protecting the inner constituents which are cathode, anode and electrolytes.
  • Materials used in the core include graphite, electrolytes such as LiPF 6 , binders such as methyl carbonate, metals including lithium, copper, nickel, cobalt, aluminium, manganese, and iron. Some of these materials such as LiPF 6 can potentially be dangerous causing explosion or emission of dangerous fumes of hydrofluoric acid.
  • Popular hydrometallurgical process are complex, expensive and introduce sulphates to the mix.
  • This invention is suitable for the treatment of all batteries, particularly solid state batteries such as NMC, LFP, Li-ion, NiMH and alkaline batteries. Batteries at all stages of life including end of life, failed or default batteries can be processed to recover all of their ingredients including binders, electrolytes, graphite, lithium, and all other metals.
  • the process can be applied to specific battery type such as NMC, or a mixture of battery types recovering whatever is in the starting mix. Ideally, the process is applied to “black mass” which is the shredded battery material without the casing.
  • the invented process can also be applied to products similar to batteries which have graphite and / or metal ions such as in petroleum derivatives, semiconductor, superconductor and electronic devices. This invention recovers all components in a safe manner with immeasurably small emissions if any. The invention does not introduce sulphates or other metal ions to the mix.
  • the first treatment step involves forming a first mixture by the addition of a solution comprising: (i) water; (ii) a first organic compound; and (iii) a second organic compound, preferably an organic solvent.
  • a solution comprising: (i) water; (ii) a first organic compound; and (iii) a second organic compound, preferably an organic solvent.
  • the water provides the majority of the solution.
  • the bulk of the water helps to provide agitation when mixed and dislodges dirt, while solvating any released reactive polar components.
  • the first organic compound is one or more selected from the group consisting of benzene, carbon tetrachloride, phenols, toluene, ketones, amines, xylenes, , alcohols, polyamides or esters.
  • the second organic compound is a solvent, and preferably is or comprises a long chain (C16+) organic compound, such as an oil.
  • step (b) is performed at a temperature of from 0 e C to 200 e C, preferably from 0 to 10 e C or from 100 to 200 e C.
  • the temperature selected will depend on the material being treated.
  • Step (b) is preferably performed for a time of from 30 minutes to 48 hours, preferably 1 to 24 hours.
  • the process then involves a step of c) filtering the first mixture to obtain a first permeate and a first residue.
  • the first permeate is a liquid which, when the method is performed on black mass from a battery, contains electrolyte and binder materials. These can be recovered from the permeate by known techniques and recycled. Even physical separation techniques can be used to achieve a good yield of these materials, with the remainder being recyclable into the process.
  • the first retentate is a graphite rich solid which is then redispersed into a second solution.
  • the step also desirably involves agitation.
  • the second solution comprises an acid or alkali, depending on the material. Using such materials helps to dissolve metals from the black mass to provide dissolved ions in solution. These can then be recovered using known techniques in the art. Preferably in step (f) the metals are recovered from the second permeate by electrolysis or precipitation.
  • filtration in steps (c) and (e) are performed using a mesh filter, preferably less than 5 micron.
  • mesh filter are suitable for trapping the graphite powder that is typically present in black mass, especially in battery applications. Suitable mesh filters of this type are readily available.
  • the method is a closed loop method, such that: (A) the first permeate is reused as at least a portion of the first solution, optionally after a separation step to remove dissolved materials from therefrom; and/or (B) the metal-depleted second permeate is reused as at least a portion of the second solution.
  • any gases released during the process steps are redissolved in water and reused in the process.
  • the method consists of the recited steps disclosed herein.
  • the invention can be put into effect without requiring a step of shredding a battery to be treated.
  • the powdered or granulated graphite-containing material is obtained in an initial step of treating an unshredded, decased battery, comprising of foils, electrolyte, binders and electrode materials, by immersion in a non-aqueous solvent, optionally with agitation.
  • decased it is meant that the outer casing and/or wrapping of the battery has been removed or at least opened to expose the battery contents.
  • the assembly is immersed in a liquid (the non-aqueous solvent) which disengages the electrode material from the foil in part or whole, thereby dropping the powder under gravity with or without agitation by mechanical or ultrasound means.
  • a liquid the non-aqueous solvent
  • the electrode materials are thereby recovered intact without measurable or significant chemical degradation, and the process of “shredding” can be eliminated. This is a significant reduction in the process complexity.
  • the non-aqueous solvent preferably comprises of one or a combination of the following polar and non-polar liquids - benzene and its derivatives, toluene, xylene, halogenated hydrocarbons, esters, alcohols, ether, cyclic ethers, acetates and ketones.
  • a chemical in solution where the added chemical is selected from a group such as organic dispersants, for example such as benzene, polyamides, alcohols or esters .
  • Step 1 Washing, with or without agitation, the filtrate of Step 1) with a chemical cleaning solution comprising for example of acid or alkali until the metal ions are dissolved.
  • a chemical cleaning solution comprising for example of acid or alkali until the metal ions are dissolved.
  • step 2 (b) Filtering, washing and drying the residue to recover the cleaned graphite.
  • step 3 (c) Using the filtrate from step 2 (b) to recover the metals by known methods such as electrolysis or precipitation.
  • Figure 1 shows a flowchart of an example of the process steps in an embodiment of the invention.
  • a powdered black mass material is provided in Step A. This is analysed to check its composition by a range of techniques, such as XRD, SEM, ICR, NMR and GCMS to determine the most suitable solutions to be employed.
  • Step B the black mass powder is mixed with a first solution. This comprises an excess of water. This provides the mass for the agitation of the black mass and acts as a diluent to help stabilise released metal compounds (such as LiPF 6 ) released from the mass.
  • a first solution comprises an excess of water. This provides the mass for the agitation of the black mass and acts as a diluent to help stabilise released metal compounds (such as LiPF 6 ) released from the mass.
  • step C the first mixture formed in step B is filtered. This recovers a safer, cleaner black mass (D) and a permeate (E).
  • the permeate (E) can be processed to remove liquid contaminants and then reused as the first solution.
  • the liquid contaminants will contain components such as binders and electrolytes when the black mass is from a battery.
  • step (E) the safer, cleaner black mass (D) is washed with an acid solution which serves to dissolve the metal from the mass and forms a second mixture.
  • the metal is typically metals such as Mn, Li, Co and Ni from battery and may be rare earth metals for petroleum coke materials.
  • step (G) the second mixture is then filtered, such as with a mesh filter to form a graphite material (H) and a second permeate (I).
  • the second permeate (I) contains the dissolved metal ions which can be separated out by standard techniques such as electrolysis. Once the dissolved metal ions are recovered the remaining acid solution can be recycled into step (E). Examples
  • Example 1 was repeated, but the benzene can be replaced with another phenol, alcohol or ketone, toluene or xylene, the rest of the process being same.
  • Example 1 was repeated, but the vegetable oil was replaced with another surfactant such as stearates, the rest of the process being same.
  • Example 1 was repeated with the raw material now being an un-shredded battery minus the outer metal case.
  • the un-shredded battery is immersed in an organic solvent liquid which will delaminate, unhinge and/ or disperse the electrode material away from the foils by acting on the adhesive and binder mechanisms of the powder to the foils and to the powder itself either in part or fully.
  • the foils can then be recovered and the liquid recycled.
  • the recovered powder can proceed to the next step of the process.
  • Example 1 was repeated, but the sulfuric acid can be replaced with other acids such as oleic acid, nitric acid, hydrochloric acid or palmitic acid - or mixtures of these the rest of the process being the same.
  • Example 6
  • Example 1 was repeated, the electrolysis process can be replaced by standard precipitation with dilute NaOH solution, ammonia solution, phosphate solution such as ammonium phosphate, carboxylate solution or mixtures thereof, the rest of the process being the same.
  • the precipitate can then be calcined at temperatures of about 30 to 1000°C, preferably 80 to 900°C to obtain compounds such as oxides.
  • Example 1 was repeated, the temperature of the water in the first step can be kept near 0°C, Rest of the process is same.
  • Example 1 was repeated, but steam or superheated steam was used up to 200°C in the first step. Rest of the process is same.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Metallurgy (AREA)
  • Mechanical Engineering (AREA)
  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Electrochemistry (AREA)
  • Secondary Cells (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

La présente invention concerne un procédé de récupération de graphite et de préférence tous les autres constituants métalliques et organiques à partir de matériaux contenant du graphite, le procédé comprenant : (a) la fourniture d'un matériau contenant du graphite en poudre ou granulé ; (b) le mélange d'une première solution avec le matériau contenant du graphite en poudre ou granulé pour former un premier mélange et agiter le premier mélange, (c) le filtrage du premier mélange pour obtenir un premier perméat et un premier résidu, (d) le mélange du premier résidu avec une seconde solution pour dissoudre le métal de celui-ci pour former un second mélange, (e) le filtrage du second mélange pour former un second perméat et un second résidu, le second résidu étant une poudre de graphite ; (f) la récupération de métaux à partir du second perméat pour former un second perméat appauvri en métal, la première solution comprenant : (i) de l'eau ; (ii) un premier composé organique ; et (iii) un second composé organique. Le processus est sûr, n'introduisant pas de sulfates ou d'ions métalliques supplémentaires et permettant une récupération complète des constituants dans un processus en boucle fermée.
PCT/EP2025/072507 2024-08-06 2025-08-05 Récupération de composants à partir de matériaux riches en carbone Pending WO2026032979A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
SG10202402356U 2024-08-06
SG10202402356U 2024-08-06
SG10202403550Q 2024-11-14
SG10202403550Q 2024-11-14

Publications (1)

Publication Number Publication Date
WO2026032979A1 true WO2026032979A1 (fr) 2026-02-12

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2025/072507 Pending WO2026032979A1 (fr) 2024-08-06 2025-08-05 Récupération de composants à partir de matériaux riches en carbone

Country Status (1)

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WO (1) WO2026032979A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210376399A1 (en) * 2017-09-28 2021-12-02 Recyclage Lithion Inc. Lithium-ion batteries recycling process
US20220384867A1 (en) * 2021-01-06 2022-12-01 Solid Power Operating, Inc. Method for separation, segregation, and recovery of constituent materials from electrochemical cells

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210376399A1 (en) * 2017-09-28 2021-12-02 Recyclage Lithion Inc. Lithium-ion batteries recycling process
US20220384867A1 (en) * 2021-01-06 2022-12-01 Solid Power Operating, Inc. Method for separation, segregation, and recovery of constituent materials from electrochemical cells

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
LIU KUI ET AL: "From spent graphite to recycle graphite anode for high-performance lithium ion batteries and sodium ion batteries", ELECTROCHIMICA ACTA, vol. 356, 1 October 2020 (2020-10-01), AMSTERDAM, NL, pages 136856, XP093322412, ISSN: 0013-4686, DOI: 10.1016/j.electacta.2020.136856 *
MA XIAOTU ET AL: "High-Performance Graphite Recovered from Spent Lithium-Ion Batteries", ACS SUSTAINABLE CHEMISTRY & ENGINEERING, vol. 7, no. 24, 16 December 2019 (2019-12-16), US, pages 19732 - 19738, XP055828684, ISSN: 2168-0485, DOI: 10.1021/acssuschemeng.9b05003 *
OLUTOGUN MAYOKUN ET AL: "Recycled graphite for more sustainable lithium-ion batteries", CARBON ENERGY, vol. 6, no. 5, 21 February 2024 (2024-02-21), XP093322372, ISSN: 2637-9368, DOI: 10.1002/cey2.483 *

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