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form factor and chemistry may be required, de- pending on the recycling process to be used. The large variety of cell sizes and shapes makes this challenging. If these were standardized to just a few variants, design of equipment to sort and pro- cess would be much simpler. This is one example of how manufacturers could design for recycling (DFR). Other DFR suggestions include using re- versible joining mechanisms to enable disassem- bly of packs (e.g., nuts and bolts instead of weld- ing). Similarly, if cells must adhere to the module, DFR would dictate using an adhesive compound that could be easily removed, perhaps with a standard solvent. Although this type of thinking is not exactly scientific research, implementation of such concepts would nonetheless help enable economic recycling. For anything but the simplest pyrometallurgi- cal processing, additional separation processes are required to separate materials from the cells. Individual cells are often disassembled manually for experimental purposes, but manual disassem- bly would be cost-prohibitive for industrial pro- cessing of small cells. Robotic disassembly could be developed, although the large variety of cell designs makes that challenging. Therefore, most processing schemes proposed for small Li-ion cells involve shredding before materials can be recovered. And the first thing to do after shred- ding is to separate out as many different compo- nents as possible. The aluminum and copper foils holding the electrode active materials are usually separated out by screening. However, a portion of the active material may still stick to the foils, so, at this stage, some process schemes add a step be- fore or after screening to drive off volatile organ- ics. This step removes the binder and reduces the quantity of active material stuck to the foils, and also evaporates the electrolyte. The electrolyte could be recovered at this stage, but processing would be required to remove decomposition products. Electrolyte recovery may be necessary to reach EU Battery Directive material recovery goals [15]. The aluminum and copper must even- tually be separated from each other as well, a pro- cess complicated by the high surface area of the small, irregular pieces. Small aluminum and cop- per foil pieces may be entrained in the black mass that remains after screening out the foils, a much more serious concern if one intends to recover an- ode or cathode material for reuse. For the hydrometallurgical route, ionic com- ponents must be separated from each other once they are in solution. Some possible methods in- clude precipitation, solvent extraction, electro- chemical processing, and membrane separation. Biological options have also been proposed. Re- covery of anode material at this stage could also be considered. The mixed alloy product from smelting also undergoes leaching and then re- quires separation. Optimization of reagents and process conditions for hydrometallurgy could im- prove selectivity and yields, resulting in lower overall costs. For direct recycling, the cathode and anode must be separated from each other using physical processes that do not disturb the particle mor- phology. Heavy liquid separation has been pa- tented, and froth flotation has also been em- ployed. The most efficient methods to separate cathode and anode from each other, and to re- move from them any traces of foils, need to be determined. Note that the discussion here as- sumes a single cathode formulation, but in fact, the shredded cells could have been a mixed batch. In that case, the cathode materials must be sepa- rated from each other to obtain the highest possi- ble product value. Although there is a patent for magnetic separation, it may not be economical, and it is unknown whether similar formulations (like two different NMCs) could be separated from each other. Methods for separating cathodes from each other or for using a mixed product would open up possibilities for direct recovery of high-value cathode products. The discussion so far has considered three distinct types of process. However, there is actually a contin- uum of potential processes between direct recycling and hydrometallurgy, where cathode is treated under conditions of increasing severity; study of these would enable understanding of the mechanisms involved in breaking down the cathode. Use of other reagents be- sides acids and bases is possible. This could lead to de- velopment of a hybrid recycling strategy that removed impurities and imperfections in the crystal structure, without losing its integrity. Another way to handle the variety of materi- als is to develop recycling processes that could produce high value products, like cathode mate- rial, directly out of a mixed feed, without break- ing down the structure. One could consider, for 8PDF Image | Lithium-Ion Battery Recycling Processes
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