Challenge for recycling advanced EV batteries
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- Lindsey Robertson
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1 Challenge for recycling advanced EV batteries
2 EV Segment addressed very well CO2 emission and low energy consumption, But. What about resources??? resources aspect must be integrated to access to a sustainable ti segment
3 Sustainability of natural resources Years of availability Tin 17 Silver 18 Gold 25 Zinc 25 Lead 28 Sulphur 35 Copper 40 Manganese 43 Aluminum Potassium Iron 440 Sources USGS 2010 OMPM 2011
4 Classification critical metals for EC (Madrid report July 2010) and EV Segment RE PGM Li Co graphite Mn Cu Al Ni The Raw Materials Initiative : a new challenge for the EU recycling industry: DG Industry and enterprise Madrid Report July 2010
5 The solution is around us! For old mine... To URBAN MINE(**) Regsitred by Recupyl in 2004 N Int. TM Register
6 Sustainability: the choice To produce 1 Ton of Lithium We need 250 T of ore (spodumène) Or 750 T of brines 28 T of Li ion batteries from mobiles/laptops Or 256 batteries for EV
7 HISTORY OF RECUPYL IN RECYCLING OF LITHIUM BATTERIES Up to 10 years experience 2002 : First study on HydroQuebec Lithium metal/polymers Batteries (now out of NDA) 2003 : Continuation of study on new chemistry 2004 : Pilot project under European Support 5th FP VALIBT 2005 : World Patent granted including LiFePO4(claims 6) 2006 : Pre industrial facility in France 50 T/y 2007 : 1 nd industrial facility in Singapore 450 T/y 2009 : 2 nd industrial facility in England 450 T/y 2010 : 3 nd industrial ll lines in USA (Michigan) 450 T/y : Pilot plant for EV Batteries (patent pending) supported by 2 EU projects 2013 : Industrial Demonstration facility for EV batteries (600T/y) supported by French Program of Investment for the Future
8 Value chain and second life of batteries Value chain and second life of batteries Battery (pack) end of life Active cells Second life (stationary, solar etc ) Test Evaluation Partial active tests of cells Non active cells Fully discharged Recycling
9 THE EV BATTERY CHAIN Btt Battery production concept for construction ti Li ion i for EV Materials processing cell module pack RECUPYL concept for «de construction» Li ion battery for EV Pack module cell processing materials
10 Dismantling of packs/ modules is mandatory for resource recovery? To dismantle, Eco conception is the real challenge for: 1 safety of operator during dismantling 2 selective access to materials 3 allows a second life for cells
11 Even the non active parts contributes to the sustainability of the end of life Average mass balance of NMC battery Dismantling is mandatory for resource recovery
12 Why to dismantle (1)? Safety aspect
13 Why to dismantle (2)? Access to expensive specific spare parts and second life of cells 13
14 But strong need of eco conception «designed for recycling» pack N 1
15 pack N 2
16 pack N 3 Gants 5000 V
17 Example of pack «designed for recycling» pack N 4 Packaging Pack BMS Cells Steel and non ferrous
18 Flows sheet of the non thermal developed process Electrical control, discharge And dismantling Dry & room temperature Physical treatment Chemical treatment
19 Dry & Room Temperature Physical Treatment 19
20 Equipement for Treatment of complete protype cells Safe and efficient mechanical treatment
21 Safe and Clean mechanical treatment: First step Recovered product after shredding : f ( ) d Mix of (NMC) oxides and Cu/Al/polymers
22 Temperature control during mechanical treatment
23 Mechanical treatment Step 2 Mix of plastics metals Mix Cathode, anode
24 Treatment of scrap production
25 Industrial pilot treatment on mechanical steps Recupyl Michigan site (recycling of EV packs and cells ) Recupyl France site Recycling of modules and cells
26 Separator and solvent recovery 26
27 Separator form Battery EV1, 2 and 3 Polyoléfine Type PP PE C H alcenes
28 Solvent separation strategy Recovery first solvent online Recovery point
29 Chemical Treatment NMC Chemistry 29
30 NMC: Strategy of treatment Co Ni Li Mn 2,1% 8,6% 2,4% 23,2% Route 2 Selective leaching Ni+Co Route 1 Total leaching Recovery of Cobalt Carbon Or mixed Ni Co compound Mn Carbon and cake for binders Métallurgy or Mn chemistry Solution for NMC precursors
31 Cobalt recovery from NMC Using a strong difference of kinetic oxidation between Co and Ni Mn Co(III) oxide Seed oxidation
32 Selective recovery of Cobalt (III) Oxide Cobalt oxide élément content Co 52.50% Cu 0.75% Al 0.59% Ni 0.49% CoOOH Fe 0.02% Mn 0.17%
33 Chemical Treatment LFP Chemistry 33
34 Chemical treatment of LPF based cathodes Black powder Redox leachning Fe(II) Hydrolyse FeOOH Lithium recovery Phosphate/carbon Li2CO3
35 Recovered iron oxide G G G G G G G G G G G G G G 35
36 Recupyl already familair with iron oxides production extractedfrom steel dust
37 The last challenge: Lithium salt suitable for the market Compound Average Request from composition technical market Li2CO3 99,5% 99,00% Fe 6 ppm 10 ppm Cu 5 ppm 10 ppm Ni < below LoD 10 ppm K 83 ppm 100 ppm Ca 133 ppm 150 ppm Na 55 ppm 800 ppm
38 Hydrometallurgy treatment at pilot level
39 Hydrometallurgy treatment at pilot level
40 Approach on Recycling Rate in regards to EU Directive Lithium ion batteries must recycled at minimum of 50% explained as metals 40
41 Recycling of NMC chemistry (hydro process) 80,0% 0% 70,0% 60,0% 50,0% 40,0% 30,0% 20,0% 10,0% 0,0%
42 Sustainability also in the model of implementation
43 UN Class 9 But. Proximity?? 9
44 USA Avoiding the Tourism of waste and heavy management of far shipment? Recupyl Battery Solutions - Michigan 2 mechanical lines AZ batteries LI batteries To be close to collection model already implemented for portable batteries by RECUPYL ASIA Recupyl Tes-Amm - Singapore 1 mechanical line LI batteries North America Europe Ai Asia EUROPE Recupyl Polska - Poland 1 sorting line 1 mechanical line AZ batteries Recupyl España - Spain 1 sorting line 1 mechanical line AZ batteries CO2 credit can also be claimed with the good choice of implementation
45 Conclusion Some metal are becoming more and more strategic due to limitation resources Better environmental technologies are needed with lower energy consumption, lower CO2 emissions and better efficiency Shipment of waste is more and more difficult ( Basel Convention, UNEP etc..) New approach of waste recycling is needed, close to collection, close to market and close the loop!!!
46 And If Resources are finite Innovation is infinite!!!!!!! A also great thanks to the Team of RECUPYL Thank you for Thank you for your attention
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