BYD's Strategies for Recycling Electric Vehicle Batteries

A recycling method for defective battery pole cores that involves disassembling and repurposing components from failed cores instead of scrapping the entire core. The method involves collecting the failed cores, expanding the pole pieces, cutting them into smaller pieces, and sorting the pieces to extract usable ones. This allows recovering and reusing pole pieces with defects like partial material loss or thickness variations. The expanded and cut pieces are then used in new battery cells. This recycles the core components instead of throwing them away, improving efficiency and reducing environmental impact compared to scrapping the entire core.

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Recycling method and device for recovering unqualified battery pole cores. The method involves unfolding the laminated pole cores to extract the individual pole pieces. This is done by cutting the periphery to separate the pole pieces from the diaphragms, then extracting the pole pieces one by one. The method improves pole piece recovery rate compared to crushing or calcining the whole cores. The device has components like cutters, shaping tools, suction cups, and clamps to perform the unfolding steps.

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A process for recovering lithium phosphate and lithium sulfate from lithium-bearing silicates like spodumene. The process involves separating impurities like fluoride, calcium, magnesium, sodium, and potassium from the lithium-bearing solution. This is done by adding phosphate and sulfate to the solution. Phosphate precipitates calcium and fluoride as calcium phosphate and fluorapatite, respectively. Sulfate precipitates magnesium as magnesium sulfate. The lithium phosphate and lithium sulfate can then be selectively precipitated from the purified lithium-bearing solution. The impurities remain in solution for further processing or recycling.

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A method to recover lithium from lithium tert-amylate waste material and prepare battery-grade lithium carbonate. The method involves dissolving the lithium tert-amylate waste in water, separating the insoluble tert-amyl alcohol, neutralizing the lithium hydroxide with hydrochloric acid, removing impurities, and adsorbing organics to obtain a low impurity lithium chloride solution suitable for preparing battery-grade lithium carbonate.

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Recycling graphene from waste lithium-ion batteries using a simple and efficient acid-peroxide leaching process to improve the quality of the recovered graphene. The recycling method involves treating the recycled graphite from the batteries with a mixed solution of acid and hydrogen peroxide. This selectively leaches impurities and weakly oxidizes the graphite, improving purity, interlayer spacing, and delamination yield. The leached graphite is then washed and dried to obtain high-quality graphene with good conductivity and reduced defects compared to direct graphene extraction from batteries.

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Method for recovering lithium, iron, and phosphorus from waste lithium iron phosphate (LFP) batteries with high selectivity, yield, and purity. The method involves a two-step leaching process to separate and regenerate the main components from the LFP waste. In step 1, lithium is selectively leached from the waste using a mixed solution of hydrochloric acid (HCl) and hydrogen peroxide (H2O2) at room temperature. This leach solution contains high lithium concentration (5-8 g/L) with low impurities (iron < 30 ppm, phosphorus < 100 ppm). In step 2, iron and phosphorus are separately leached from the LFP waste using an ammonium sulfate (NH42SO4) solution at elevated temperature (

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Regenerating lithium iron phosphate (LiFePO4) positive electrode material from waste lithium iron phosphate (LiFePO4) or lithium iron phosphate battery anode recycling. The regeneration involves dissolving away the carbon coating and surface lithium-depleted regions of the waste material using weak acid. The remaining core is then used as a seed for growing new LiFePO4 shell layers around it. This core-shell structure improves conductivity, charge/discharge capacity, and cycle life compared to the original waste material.

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Method and system for sorting retired batteries by echelon utilization to improve efficiency and widen environmental applicability compared to traditional indoor sorting methods. The method involves detecting thickness and AC resistance of retired batteries, calculating capacity using a pre-obtained formula, and determining if the battery is qualified. This allows portable handheld tools to sort batteries outdoors without requiring specialized equipment. It avoids testing batteries with unqualified appearance, reduces tests, and improves sorting speed. The system includes a portable thickness and resistance detector connected to a data processing device that calculates capacity using a pre-obtained formula.

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Process for extracting lithium from uncalcined lithium-bearing silicates like spodumene without roasting. The process involves heating a slurry of the silicate and a caustic solution in an autoclave to convert it into a lithium-rich sodalite phase. This phase is then leached to extract lithium into a solution. The leach solution can be further processed to recover lithium carbonate, lithium phosphate, lithium sulfate, or lithium hydroxide. This avoids the high-energy calcination step used in traditional lithium extraction processes.

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Converting lithium phosphate into a low-phosphate lithium solution suitable for making saleable lithium products like carbonate or hydroxide. The process involves dissolving lithium phosphate in acid, treating with a phosphate carrier hydroxide to precipitate phosphate, separating the phosphate, then treating the residual phosphate with a strong hydroxide base to convert it into phosphate carrier hydroxide. This allows recycling phosphate from the lithium solution for reuse. The lithium solution after phosphate removal has <10 mg/L phosphate suitable for further processing into marketable lithium products.

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A method for recycling lithium from waste lithium iron phosphate batteries to extract high-purity lithium carbonate. The method involves dismantling the batteries, separating the lithium iron phosphate powder, roasting it with magnesium salts and oxygen to convert the iron, leaching with acid to extract lithium, removing impurities with bases, and precipitating lithium carbonate.

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A method for treating waste lithium battery cathode material to recover valuable metals like nickel, cobalt, manganese, and lithium from the waste. The method involves steps like calcination, acid leaching, fluoride extraction, and precipitation. The calcination step converts the battery cathode waste into oxide forms. The acid leaching extracts the metals. The fluoride extraction removes lithium and other metals as fluorides. The final precipitation separates the metals. This integrated process achieves high metal recovery, efficient extraction, and environment-friendly treatment.

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