Post on 13-May-2018
Valorisation of battery recycling slagsF. Verhaeghe1, F. Goubin1, B. Yazicioglu2, M. Schurmans1, B. Thijs1, G. Haesebroek1, J. Tytgat2, M. Van Camp1
1 Umicore Group Research & Development2 Umicore Battery Recycling
Outline
Introducing Umicore
Rechargeable battery landscape
Need for recycling
Umicore’s battery recycling flowsheet
Slag valorisation
Conclusions
28/04/20112 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Outline
Introducing Umicore
Rechargeable battery landscape
Need for recycling
Umicore’s battery recycling flowsheet
Slag valorisation
Conclusions
28/04/20113 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Outline
Introducing Umicore in 3 slides...
Rechargeable battery landscape
Need for recycling
Umicore’s battery recycling flowsheet
Slag valorisation
Conclusions
28/04/20114 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Key megatrends for Umicore
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· More stringent emission control
· Resource scarcity
· Renewable energy · Electrification of the automobile
Umicore fit with megatrends
28/04/20116 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Electrification
of the automobile
Resource
scarcity
More stringent
emission control
Renewable
energy
We are the largest recycler of precious metals; we
are able to recycle more than 20 different metals
We are a leading producer of key materials for
rechargeable batteries for laptops, mobile phones
as well as electrified vehicles
We provide catalysts for 1 out of 3 cars in the
world as well as for trucks & non-road vehicles
We supply key innovative materials for high-
efficiency solar cells and other photovoltaic
applications
Umicore’s business approach
28/04/20117 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
“Less is more”Metal related materials can be efficiently and infinitely recycled, which makes them the basis for sustainable products and services
material
solutionsMetals
Application
know-how
Recycling
Material
solutions
Chemistry
Material science
Metallurgy
Outline
Introducing Umicore
Rechargeable battery landscape
Need for recycling
Umicore’s battery recycling flowsheet
Slag valorisation
Conclusions
28/04/20118 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Types of batteries
28/04/20119 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Laptop batteries
Mobile phone batteries
HEV-PHEV-EV batteries
Types of batteries
28/04/201110 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
0
0.2
0.4
0.6
0.8
1
1.21.4
Emerging MatureGrowingPacing
LiCoO2LiMn2O4
NCA
LiFePO4
LiMn1.5Ni0.5O4
Li(Ni0.5Mn0.3Co0.2)O2
LiMnM’PO4 LiyVPOx
Li1+X(Ni1/3Mn1/3Co1/3)1-XO2
HLM
Li(Ni0.4Mn0.4Co0.2)O2Li(NMCM’)O2
Li1+X(Ni0.4Mn0.3Co0.3)1-XO2
Evolution on battery chemistry
Types of batteries
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Increasing volumes & demand
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
2003
2005
2007
2009
2011
2013
2015
2017
(in MWh/ year)
Portable electronics Power tools (P)HEV / EV
Power demand for Li-Ion batteries
0
10
20
30
40
50
60
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
(indexed versus 2009)
End-of-Life batteries
Batteries from service repairs
Battery production scrap
Potential recyclable (H)EV battery materialPower demand for Li-ion batteries Potential recyclable (H)EV battery material
Outline
Introducing Umicore
Rechargeable battery landscape
Need for recycling
Umicore’s battery recycling flowsheet
Slag valorisation
Conclusions
28/04/201112 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
In the core of the megatrends
28/04/201113 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
· More stringent emission control
· Resource scarcity
· Renewable energy · Electrification of the automobile
Legislative framework
28/04/201114 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Waste Framework
Directive
Battery
Directive
(BD)
End of Life
of Vehicles
(ELV)
Waste of
Electrical and
Electronic
Equipment
(WEEE)
• Waste vs. by-
products
• Hazardous
waste list
• Transport rules
Legislative framework
WEEE directive
obligation to remove batteries
ELV directive
End of Life concerns to be addressed in design phase
feasibility of reuse & recycling to be demonstrated
promotes use of recycled materials
target by 2015: reuse + recycling = 85%
obligation to remove & collect batteries
28/04/201115 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Legislative framework
Battery directive
scope: all batteries (incl. rechargeable) except military & space includes (H)EV’s
producers have to take battery back
landfill or incineration explicitly forbidden
debate on possible conflict with ELV
clear collection & recycling targets collection: 25% by September 2012 – 45% by September 2016
ban on landfill
recycling efficiency target: > 50% by September 2011
debate on method of calculation
28/04/201116 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Outline
Introducing Umicore
Rechargeable battery landscape
Need for recycling
Umicore’s battery recycling flowsheet
Slag valorisation
Conclusions
28/04/201118 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Closing the loop
28/04/201119 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
material
solutionsMetals
Application
know-how
Recycling
Material
solutions
Chemistry
Material science
Metallurgy
Closing the battery loop
28/04/201120 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Battery recycling flowsheet
28/04/201121 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Battery recycling flowsheet
28/04/201122 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Battery recycling flowsheet
Step 1: smelting & energy valorisation
process no pre-treatment (except for HEV)
evaporate electrolyte
melt metals
recover calorific capacity
reduction oxides to metal using graphite electrode material
production alloy (Co-Cu-Ni-Fe)
slag (Li)
gas
28/04/201123 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Battery recycling flowsheet
Step 2: refining & purification of metals
process leaching in sulphuric acid
several purification steps
solvent extraction for NiSO4
production CoCl2
NiSO4 → Ni(OH)2: closing NiMH loop
Step 3 & 4: oxidation to Co3O4 + production of LiCoO2
oxidation of pure CoCl2 to Co3O4
Co3O4 + Li2CO3 → LiCoO2: closing Li-ion loop
28/04/201124 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Outline
Introducing Umicore
Rechargeable battery landscape
Need for recycling
Umicore’s battery recycling flowsheet
Slag valorisation
Conclusions
28/04/201125 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Slag valorisation
Slag properties
main components: CaO – Al2O3 – SiO2
minor components: FeOx – Li2O – MnO
particle size: 0-4mm and 4-32mm
Regulation
VLAREA standards of OVAM
compliant with REACH – CE marking – waste & construction directives
leaching properties
28/04/201126 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Slag valorisation
Construction applications
aggregate – cement raw material – filling material in concrete
used as filling in construction of industrial facility in Sweden
LA-test: resistance to fragmentation LA < 30: suitable for coating & road surface treatments
MD-test: resistance to wear MD < 20: suitable in concrete
28/04/201127 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Tests EN Standard Slag (Fine & Coarse aggregate)
Free CaO (%) 1744-1 § 18 (1998) 0.22
Free MgO (%) 1744-1 § 18 (1998) <1%
Los Angeles Coefficient (La) 1097-2 (1998) 24
Micro Deval Coefficient (MD) 1097-1 (1996) 10
Slag valorisation
CO2 neutrality
nearly 5% of man-made CO2 emissions from cement
secondary materials avoid CO2 emission
transition limestone → CaO already made
Li-source in glass/ceramics
vitro-ceramic glass: Li for heat resistance
28/04/201128 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Slag valorisation
Li-valorisation
28/04/201129 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Outline
Introducing Umicore
Rechargeable battery landscape
Need for recycling
Umicore’s battery recycling flowsheet
Slag valorisation
Conclusions
28/04/201130 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.
Conclusions
Rechargeable batteries are everywhere
Megatrends
resource scarcity
electrification of cars
Legislative drivers towards recycling
Umicore closes battery loop
Slag valorisation
application in construction
Li-valorisation
28/04/201131 Second International Slag Valorisation Symposium │ Valorisation of battery recycling slags - F. Verhaeghe et al.