Separation Processes for Electric Vehicle Battery Recycling

Method for recycling battery electrodes that involves washing and rinsing the electrodes multiple times using ultrasonication and spraying to delaminate the active material from the current collectors. The electrodes are first moistened, then washed and rinsed in two stages using ultrasonication at different frequencies. This removes larger particles in the first stage and finer particles in the second stage. The method improves electrode recycling by using optimized washing steps to separate the active material and current collectors.

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Waste lithium battery recycling device for new energy vehicles that efficiently separates and recycles battery components without mixing them. The device has three recycling areas: positioning oscillation, shell separation, and shell crushing. The positioning oscillation area holds the battery and vibrates it to loosen connections. The shell separation area removes the outer case. The shell crushing area flattens the remaining battery components. This sequential separation prevents mixing of different materials.

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Fully automatic lithium-ion battery recycling system that enables efficient separation and processing of battery components through a multi-stage process. The system comprises primary pulverization, air separation, magnetic separation, steel shell collection, and high-energy shearing, followed by a vibration separator. The process achieves separation of battery components through a combination of air separation and magnetic separation, with the collected materials then being processed through a series of mechanical and chemical treatments.

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A lithium battery positive plate separation device that optimizes the recycling process by removing impurities from the positive plate before processing. The device employs a dual-step approach: first, the positive plate is cleaned through high-pressure water jets to remove attached materials, followed by a drying step to separate the plate from its adherents. This approach significantly enhances the separation efficiency and purity of the positive plate, while also preventing secondary pollution from the attached materials during the subsequent drying process.

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A sorting device for decommissioned power battery diaphragm pole pieces that improves recovery purity of positive and negative electrodes through precise separation of pole pieces and diaphragms. The device employs a combination of mechanical separation, eddy current sorting, magnetic separation, and magnetic strengthening mechanisms to separate pole pieces from diaphragms, followed by precise separation of positive and negative electrodes. This enables enhanced recovery of high-value components while minimizing energy consumption and sieve hole blockages.

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A method for recycling lithium-ion batteries through a novel pretreatment process that enables efficient separation of materials. The process involves heating the battery residue to enhance material separation, followed by crushing and sieving to control particle size. The crushed material is then subjected to magnetic separation to separate steel slag, copper flakes, aluminum foil, and graphite. The graphite is separated through wet leaching, and the remaining materials are processed to recover copper, aluminum, and other valuable components. The method achieves higher purity and recovery rates compared to traditional battery disassembly methods.

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A recycling process for extracting metals from used lithium-ion batteries without manual separation of lead-acid solution. The process involves crushing the batteries to extract the metals and separate the lead-acid solution. The crushed batteries are fed into a recovery box with a shaking screen to filter out the lead-acid solution. The filtered batteries are then moved to a water storage tank where they sink and metal floats to the surface. A shovel collects the metal and moves it to a separation box with a water surface push plate. The push plate scoops up the plastic and pushes it to the side. The walking roller on the bottom of the push plate follows a sloped guide to lift the push plate. This separates the plastic from the water storage tank. The plastic falls into a collection box. The metal floats in the water and is moved to a metal collection bag.

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A method for precise separation of cathode materials from lithium-ion battery waste using electrostatic and magnetic separation. The process involves crushing the battery waste, followed by magnetic separation to separate iron and other ferromagnetic materials. The magnetic separation is then followed by electrostatic separation to separate the remaining materials, including copper, aluminum, and graphite. This multi-stage separation process enables the precise sorting of cathode materials, achieving higher purity levels compared to traditional single-stage separation methods.

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A waste battery recycling device that improves the efficiency of battery material separation from spent electric vehicle batteries. The device comprises a frame with inlet and outlet ports, a power mechanism, crushing mechanism, and air-flow screening mechanism. The power mechanism drives the crushing mechanism, which pulverizes the battery components. The air-flow screening mechanism separates the crushed materials from the battery casings and other contaminants. The crushed materials are then processed through a magnetic force division sieve, which further separates the metal components from the non-metallic materials. The processed materials are then stored in a discharge port for further processing or reuse.

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Device for processing decommissioned lithium battery electrolyte residues to prevent environmental hazards. The device contains a controlled environment where the battery electrolyte is processed in a manner that prevents the formation of hazardous fluoride and phosphorus compounds. The device employs a controlled atmosphere and precise temperature and pressure conditions to safely handle the hazardous electrolyte while maintaining its integrity.

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A waste ternary lithium battery recycling process that employs a tiered extraction method to recover valuable metals from spent lithium-ion batteries. The process involves heating and evaporating the battery materials, followed by magnetic separation and electrostatic separation. The resulting material is then mixed with an acid solution to extract metals, which are then further processed through multiple stages of extraction and purification to minimize contamination and improve recovery efficiency.

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A waste battery recycling processing method that enables efficient sorting and transportation of mixed battery waste through controlled separation and collection. The method involves sorting battery types using a vibrating plate and conveying system, where waste batteries are first placed on a vibrating plate and then separated into distinct categories based on their physical characteristics. The sorted batteries are then transported to a sorting facility where they are further processed for recycling.

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A method for non-hazardous battery recycling and dismantling that automates the disassembly process through intelligent sorting, classification, and recycling. The system employs advanced gas detection and sensor technology to identify battery types and integrity before disassembly, enabling precise control over the recycling process. The system integrates vacuum, gas, and liquid processing, with automated cutting and thruster systems to efficiently dismantle batteries. This approach eliminates manual labor and hazardous conditions associated with traditional recycling methods.

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A lithium-ion battery recycling pretreatment method that enhances the recovery of valuable metals through a dual-activation process after initial thermal treatment. The method combines ball milling with an advanced additive system to activate the electrode material, followed by selective dissolution and leaching of the resulting active material. This approach addresses the limitations of conventional pretreatment methods by providing both mechanical activation and chemical activation pathways for metal recovery.

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Vacuum-based method and device for safely and efficiently dismantling lithium-ion batteries in a controlled environment. The method utilizes a specially designed vacuum chamber with automated disassembly capabilities, where the battery is first removed from the cell and then broken down into its constituent components through precise mechanical disassembly. The process is performed in a sealed environment with controlled atmosphere conditions, allowing for the safe handling of hazardous materials and preventing fire hazards. The dismantling process is further supported by a vacuum system that captures and recovers the generated gases, ensuring a controlled and environmentally responsible disposal process.

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A novel lithium battery recycling process that enhances material recovery through a multi-stage approach. The method involves a magnetic separation stage followed by a high-pressure leaching process, and then a purification step. The process utilizes a unique combination of magnetic separation and high-pressure leaching to separate lithium-ion battery components, while the high-pressure leaching process enables the extraction of valuable lithium and other metals. This multi-stage approach addresses the challenges of traditional lithium-ion battery recycling by providing a more comprehensive and efficient recovery process.

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Method for processing waste power lithium-ion batteries to recover valuable components while minimizing environmental impact. The process involves a multi-step sequence of mechanical separation, chemical treatment, and purification to extract valuable materials such as aluminum, copper, and graphite. The treatment includes crushing, volatilization, decomposition, alkaline washing, and pyrolysis steps to ensure the recovery of hazardous materials while maintaining their chemical integrity. The method enables the efficient recovery of valuable components from spent lithium-ion batteries while protecting the environment through controlled chemical processing.

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A novel recycling method for lithium-ion batteries that enables selective extraction of valuable metals while minimizing chemical reagent consumption. The process employs a hierarchical approach involving multiple stages of separation, including mechanical sieving, chemical treatment, and selective precipitation. The first stage of mechanical separation removes the battery components, followed by chemical treatment with sodium persulfate to dissolve the battery materials. The resulting slurry is then subjected to selective precipitation using sodium hydroxide, which selectively precipitates the desired metal ions while leaving the battery components behind. This multi-stage approach enables the efficient recovery of valuable metals from lithium-ion battery waste without requiring the use of harsh chemicals.

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A device for recovering lithium-ion battery electrolyte from spent batteries through a controlled evaporation process. The device comprises a furnace, vapor cooler, and collection system to manage the electrolyte vapor stream. The furnace uses electric or microwave heating to vaporize the electrolyte, while the vapor is cooled to prevent dust formation. The vapor is then collected and processed through a series of separation steps, including evaporation, condensation, and separation of the liquid and gas phases. The liquid phase is then processed through a fluoride removal step, followed by liquefaction using a pressurized or refrigerated process. The resulting liquid electrolyte is then treated with activated carbon to remove trace organic compounds.

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A method for recovering unformed sheet waste from lithium-ion battery production through a multi-step process that addresses the conventional separation challenges. The process involves crushing, roasting, washing, sieving, settling, and drying of the unformed material, followed by separation of the current collector from the electrode material. The current collector is then further processed to produce a high-purity material suitable for recycling.

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Automated lithium-ion battery shell core separation system for recycling. The system comprises a vibrating plate, battery transmission mechanism, ring cutting mechanism, slitting mechanism, sorting organization, and a shell core separation device. The system enables precise separation of battery components through controlled cutting and slitting operations, while maintaining a safe working environment through the use of a dust collection system and gas recovery mechanism.

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A novel method for automated lithium-ion battery recycling that enables efficient separation of battery components through a single-step process. The method involves cutting the battery into precise blocks, which are then processed in an oxygen-controlled environment to separate key components like cathode materials, aluminum foil, and copper components. The separated components are then processed for recovery of valuable materials, eliminating the need for multiple processing steps and conventional sorting methods. The method achieves high purity recovery rates while minimizing environmental impact through controlled processing conditions.

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Battery resource recycling system for end-of-life electric vehicle batteries that extract valuable materials like lithium, cobalt, nickel, manganese, copper, and aluminum. The system consists of 8 steps: pretreatment, battery disassembly, electrolyte recovery, separator separation, positive/negative electrode material recovery, non-metallic material recovery, valuable metal recovery, and waste treatment. It uses mechanical, physical, and chemical processes to separate and purify the valuable components from the battery waste.

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A power battery disassembling device for recycling that provides enhanced safety and environmental protection through automated separation of the battery compartment. The device features a controlled access path between the worker and the battery compartment, eliminating the risk of fire hazards and ensuring a safe working environment. The device also incorporates a secure containment system that prevents hazardous materials from escaping during the recycling process.

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A method for recovering lithium-ion battery electrolyte that minimizes environmental impact and contamination. The recovery process utilizes a combination of advanced materials like copper or diamond to enhance the separation of lithium ions from the electrolyte, while maintaining the integrity of the battery components. The process involves a controlled thermal treatment step that selectively precipitates the lithium ions from the electrolyte, followed by a precise separation of the precipitated lithium ions from the remaining electrolyte components. This approach enables the recovery of lithium-ion battery electrolyte while preserving the structural integrity of the battery components.

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A method for recovering iron from spent lithium-ion batteries through a two-step process that improves efficiency and purity compared to existing methods. The method involves crushing the spent lithium-ion batteries to release the iron content, followed by a selective leaching process to separate the iron from the remaining battery materials. The crushed lithium-ion batteries are first crushed to release the iron-rich electrolyte and metal, followed by a selective leaching process that selectively dissolves the iron while leaving behind the battery materials with lower iron content. This two-step process enables the efficient recovery of iron from spent lithium-ion batteries, with improved purity compared to traditional crushing followed by leaching methods.

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A method and equipment for safely and efficiently separating lithium-ion battery components during recycling. The process involves cutting the battery casing under the cover plate while maintaining the battery's structural integrity. The cutting mechanism creates an incomplete cut, allowing the cover plate to remain intact while the casing is separated. The cover plate is then removed, followed by the core separation through a separate process. This approach eliminates the need for external forces and abrasive materials, reducing the risk of thermal runaway and short circuits.

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A lithium-ion battery waste sorting device that enables efficient separation of battery materials through a multi-step process. The device uses a combination of mechanical and chemical methods to separate lithium, cobalt, nickel, and other critical components from battery waste. The process involves crushing the battery cells, followed by a series of mechanical separation steps, and then chemical processing to extract the valuable materials. This multi-stage approach ensures comprehensive material recovery while minimizing environmental impact.

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A method for recovering and recycling lithium iron phosphate (LiFePO4) batteries through controlled thermal decomposition and chemical processing. The process involves thermal treatment of the battery cells to degrade the iron phosphate structure, followed by chemical treatment with specific reagents to extract the iron and other valuable materials. The extracted materials can then be processed into high-quality cathode materials, nickel, cobalt, and other valuable components for further recycling or reuse in new battery production.

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A comprehensive lithium-ion battery recycling method that addresses the environmental and operational challenges of lithium-ion battery waste management. The process involves recovering the cathode and anode materials through a multi-step separation and processing sequence, enabling the recovery of valuable resources such as lithium, iron, and graphite. This comprehensive recycling approach addresses the conventional limitations of lithium-ion battery anode material recovery by providing a comprehensive recycling solution that can be applied to both positive and negative electrodes.

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A low-cost, environmentally friendly lithium-ion battery recycling process that enables the safe and efficient extraction of valuable materials from spent batteries. The method employs a multi-step approach that utilizes a controlled atmosphere cleaning process followed by a specialized extraction system. The cleaning process maintains a nitrogen atmosphere while injecting cleaning solutions, preventing combustion and ensuring the battery remains stable. The extraction system then removes the remaining electrolyte and other contaminants through vacuum processing, enabling the recovery of valuable cathode materials like LiFePO4.

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A process for recovering valuable metals from lithium-ion batteries through selective processing of their constituent materials. The method involves separating the battery components by their chemical properties, with specific targets including copper, aluminum, iron, cobalt, and lithium. The battery is first crushed and separated into its constituent materials, which are then processed through selective chemical treatment to extract the desired metals. The extracted metals can be further refined and purified to produce high-quality recyclable materials.

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Battery recycling device for rapid and efficient battery shell separation. The device uses a unique combination of mechanical and magnetic separation processes to quickly and accurately separate battery casings from their broken shells. The system employs a proprietary combination of crushing and separation technologies to achieve rapid shell separation, eliminating the need for manual sorting and classification. This enables the efficient recycling of battery casings without the associated security risks and slow dismantling rates associated with traditional methods.

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A method for processing lithium-ion battery waste containing lithium hexafluorophosphate (LiPF6) through a novel chemical treatment process. The method involves treating the waste solution with concentrated sodium hydroxide (NaOH) to initiate a rapid hydrolysis reaction that converts LiPF6 into lithium phosphate precipitate. This precipitate is then separated from the liquid phase through filtration and dissolved into the aqueous phase. The process achieves efficient desalination of the LiPF6-containing waste by converting it into a solid precipitate that can be easily separated from the aqueous phase.

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A novel, chemical-free lead-acid battery recycling process that enables efficient and environmentally friendly recycling of lead-acid batteries through a multi-step mechanical separation process. The process involves stacking batteries in a controlled environment, scanning them with X-ray machines to identify cell dimensions, and then using a precision cutting mechanism to separate the batteries based on their dimensions. The cutting mechanism is designed to maintain the original battery geometry while accurately identifying and separating the different battery sizes. This approach eliminates the need for chemical reagents and conventional crushing methods, significantly improving the recycling efficiency and reducing environmental impact compared to traditional methods.

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A method for recovering lithium-ion batteries containing lithium cobalt oxide and graphite through a novel processing sequence that eliminates the need for complex chemical processing steps. The process involves crushing the battery waste into a mixed material, separating the lithium cobalt oxide and graphite, and then using electrostatic separation to collect the resulting lithium cobalt oxide and graphite. This approach enables efficient recovery of valuable lithium materials without the environmental and economic drawbacks associated with traditional chemical processing methods.

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A method for processing spent lithium-ion battery cathode materials to produce high-purity nickel-cobalt-manganese cathode precursors. The process involves chemical extraction of impurities from spent cathode materials, followed by precise purification of the resulting liquid to achieve high-purity nickel-cobalt-manganese solutions. These solutions can be directly used to produce cathode precursors for lithium-ion battery production, enabling the recovery of valuable materials from spent battery waste.

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Automated battery dismantling system for power battery recycling that eliminates manual labor and minimizes safety risks. The system employs a robotic feeding mechanism to transfer battery power from the silo to a horizontal platform, where it is clamped and positioned for cutting. The cutting mechanism uses a battery head clamping system to secure the battery cells during the cutting process, followed by a coring mechanism to extract the battery components. The system integrates a dust containment system to protect personnel and equipment, and includes a remote monitoring system for continuous process control.

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Method for recovering valuable materials from lithium-ion battery cathodes and film through a novel recycling process. The process involves converting the organic electrolyte and lithium hexafluorophosphate byproducts into a new material through a chemical synthesis route, enabling the reuse of these materials as raw materials for producing new battery components.

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Discharging lithium-ion batteries in a controlled manner to prevent explosion during the recycling process. The method involves electrolyzing water to discharge the battery, rather than traditional methods of discharging through mechanical means. This controlled discharge process eliminates the risk of cell detachment during the recycling process, ensuring safe and efficient battery disassembly. The method is particularly effective for small lithium-ion batteries that pose a significant explosion risk during traditional discharging methods.

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Eco-friendly method for recycling used lithium iron phosphate (LFP) batteries to extract valuable materials like iron, lithium, and phosphorus. The process involves leaching the spent batteries with aqueous ammonia at room temperature to dissolve the iron, then separating the iron-rich solution and precipitating out the iron hydroxide for recycling. The remaining leachate is treated with hydrochloric acid to precipitate out lithium phosphate for recovery. This closed-loop process avoids using organic solvents and high temperatures, making it more environmentally friendly and cost-effective compared to conventional battery recycling methods.

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A method for treating lithium-ion battery waste through a closed-loop process that converts the electrolyte and solution into valuable resources while minimizing environmental impact. The process involves treating the battery waste electrolyte through electrolysis to produce a valuable liquid waste stream, which is then processed into a valuable byproduct. The byproduct can be used as a feedstock for the production of new battery materials, such as lithium cobalt hydroxide, while the treated waste is treated to remove contaminants and pollutants. This closed-loop process enables the recovery of valuable materials from lithium-ion battery waste while minimizing the generation of hazardous waste.

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A method for recovering valuable metals from waste slags generated during nickel-cobalt smelting through a novel process that utilizes the natural properties of the slags to extract metals. The process involves dissolving the slags in sulfuric acid, then reducing the resulting metal-rich solution to produce a high-quality nickel-cobalt metal product. The solution is then treated with sodium fluoride to selectively precipitate metals like manganese, zinc, and aluminum, which are then recovered as a valuable by-product. This approach eliminates the need for expensive secondary smelting processes and reduces environmental impact by utilizing the natural composition of the slags to produce valuable metals.

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