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instance, if a mixture of NMC cathode materials with different percentages of nickel, manganese, and cobalt could be treated with additional quan- tities of these to adjust the mixture into a desired uniform composition product. 6.2 Reuse of Structure Separating everything may not always be the best route. Another research direction approaches used batteries from the standpoint of retaining and utilizing as much of their existing structure as possible. This category is exemplified by second- life—simply using the entire battery (or the mod- ules) again in a less demanding service. Second- life is discussed elsewhere [26][27]. The bottom line is that second-use may be economic for some, but not all, markets. It has also been sug- gested [28] that other battery types be used for utility and home storage, and cobalt-containing batteries recycled immediately to bolster cobalt supply. This paper assumes that batteries actually ar- riving at recycling facilities cannot be used fur- ther. Most recycling process flows either start with size reduction or direct feed of cells or mod- ules into a furnace. It may be possible, however, to rejuvenate spent cells [25], a process that may be considered as direct recycling in situ. Flushing cells with a solvent would remove the SEI on the electrodes and unclog the separators. Possible solvents include CO2, alcohols, or aprotic polar solvents like NMP, DMF, or acetone. New elec- trolyte could then be added and the solvent and old electrolyte recovered. Perhaps relithiation could be accomplished as well. Such a scheme re- quires a two-way valve to allow liquid in and out of the cell. Obviously rejuvenation would be dif- ficult for small cells, but could be enabled as part of the design of larger cells. chemistry. Flexible process design would enable use of shifting feedstock. Before scaling up any process, it is important to make sure that all haz- ardous compounds, even in trace quantities, have been tracked. In particular, the fluorine in electro- lyte salts and binder must be accounted for. Even if practical recycling processes are de- veloped, the product must find a market. That means that the reliability of recycled materials must be assured. This would entail long-term test- ing and development of strict material composi- tion and performance standards. 6.4 Modeling of Recycling Processes Process modeling enables prediction of pro- cess behavior and costs without actually building a plant, and saves considerable time and money in planning new facilities. Argonne is developing a high-level, closed-loop battery lifecycle model called ReCell to provide cost and environmental impacts through all stages and processing steps of the life cycle of a Li-ion battery. This tool will pro- vide insight into the relative impacts of different battery recycling paths and enable stakeholders to simulate and compare both costs and environmen- tal impacts. It can also facilitate DFR analyses. The model will provide a high-level preview of the implications of proposed process and chemistry changes when detailed process data are input. The tool is intended to help develop improved battery recycling processes and verify critical materials re- covery. This knowledge will accelerate battery re- search and guide its direction towards optimization of process-specific and overall economic, energy, and environmental impacts. 7. Conclusions There is no simple route to recycling of Li- ion batteries. These are varied and complicated products, whose design continues to evolve. Their recycling would have environmental and hopefully economic benefits, but none of the sev- eral methods for their recycling is ideal; each has its own drawbacks and advantages. In this paper, we have suggested some possible directions for research that might lead to better recycling pro- cesses, so if and when large numbers of electric vehicles are built, we will know what to do with the batteries when they reach their end-of-life. 6.3 Process Design Other research ideas do not fall into clear cat- egories. All of the processes discussed have room for process optimization. Reagents, reaction times and temperatures, unit process order, pre- treatment options, and batch size (or throughput, if run continuously) will all affect product com- position and process economics, and they may optimize differently as a function of battery 9PDF Image | Lithium-Ion Battery Recycling Processes
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