[email protected] – [email protected] recycling of li-ion and nimh batteries from...
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Recycling of Li-ion and NiMH batteries from electricvehicles: technology and impact on life cycle
Dr. Jan Tytgat, General Manager, Umicore Battery Recycling, Olen, Belgium
Co-Author: Dipl.-Ing. Frank Treffer, Umicore Battery Recycling, Hanau-Wolfgang, Germany
[email protected] – [email protected] Belgian Platform EV 20110331
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EHS
Volume
(H)EV market
Value
Metals: Y but
Compounds: N
Reuse: ?
Environment-health-safety
Regulatory framework:
EU: Raw Materials Initiative & Directives: Waste Framework, Battery, End of Life Vehicles
battery recycling will mainly be volume and regulatory driven
Recycling drivers
EV batteries are ‘industrial batteries’ recycling is compulsory
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Economics
Technology
Material valueEconomy of scale
EnvironmentCore competenceState of the Art
LCA impact categoriesRecycling v. downcycling
Strategic choices
Several aspects to be considered!
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Fundamental process options
sizeDedicated
Mainstream
Small, highly dedicated
processes: compound recovery
Mid-large size, early
standardization: element recovery
Large-huge size, connect to
mainstream processes
(steel, mining)
Focus on compound recovery (value); but:
• small volumes
• quality ?
• battery chemistry evolution (lifespan > 10 y)
difficult to get qualified
Rigid processes; no feed risks to avoid process disruptions.
Battery chemistry is complex and dynamic
Focus on metal recovery, designed for broad family ranges:
• robust process
• trend: less valuable metals
Scale effect
Umicore model
Strategic choices
Technology choice
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Strategic choices
Combined Pyro + Hydro
Dismantling
Plastics
Al, Steel
Cu, BMS
Modules cellsmodules
smelter shredder
alloy slag flue dust fluff metals black mass
Refining(hydro)
Cu Fe Co Nimetal/compounds
Construction or Li/REE valorization
land fill(30%)
land fill(3%)
metal salts
graphite (land fill)
Remelting
sorting
Cu Fe Al
Hydro process
Combined Mechanical + Hydro
Umicore technology: combined Pyro + Hydro, because:
• Close to zero waste, full energy recovery
• Robust process, suited for all Li-ion + NiMH
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The Umicore Battery Recycling processDismantling line at UBR Hanau
Project funded by BMU: LiBRI
Dismantling of battery packs to module level: possibility to sort ‘good’ modules
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Ni
Fe Cu
INPUT
Ca/Si/Al/Mn aggregates
Co / Cu / Ni / Fe granulated alloy
OUTPUT
OUTPUT
Cement industry
Further Refining
Co Ni Fe
CuCoSX de-Fe de-Cu
Smelting
(CoCl2)
LiCoO2
+ Energy Valorization
AlloyRefining
Ni(OH)2
FiringWith LiCO3
Pure newBattery
Precursors+ oxidation(Co3O4)
NiSO4
Li (potential to recover)
RE’s
The Umicore Battery Recycling process
5 years of experience;
2011: new, improved smelter
EV modules
EV pack dismantling modules
Portable Rechargeable Batteries
Production scrap
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New UBR battery smelter
Up & running: spring 2011
capacity: 7000 ton/y
No further dismantling, crushing,… : no exposure to operators and environment
For any size of batteries
Energy efficient; no hazardous emissions
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Cu
Ni
AlLi
MnCo
REE
C
K
ClP
F
BO
H
CuNi Al LiMnCo REE
C
K
Cl
P
F
B
O
H
O
Recycled as products andby-products
Recovered
Emitted
Collected
Recycling Efficiency:
RE: Above
50% EU target
Fe
Fe
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LCA definition according to ISO 14040
"A systematic set of procedures for compiling and examining the inputs and outputs of materials and energy and the associated environmental impacts directly attributable to the functioning of a product or service system throughout its life cycle.”
LCA: a tool for assessment of Environmental Impact
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LCA is an iterative process
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Inventory Classification Characterisation and Normalisation
CO2 Carcinogenicity
Respiratory organic pollutionRespiratory inorganic pollution
crude oil Radiation
Ozone layer depletion
NOX Climate change
EcotoxicityAcidification, eutrophication
iron (ore) Land use
Mineralsphosphates Fossil fuels
W e i g h t i n g
Indicators (points)Ecosystem
quality
Ressources
Human health
Essential: process of grouping and weighting
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LCA studies involving Umicore Battery Recycling process
Overview:
Simplified LCA on battery cell from SAFT (battery chemistry LCO)
LCA on Prius battery (NiMH battery)
LCA on production of NMC active cathode material
Several ongoing LCA studies with customers, to be published in near future
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Simplified LCA by SAFT
Goal & scope and selected impact categories:
to compare impact of recycling on CO2 production
and energy consumption for the production of a
Saft MP 176065 Integration® cell
Production of LiCoO2 material : Option 1 : from Ni, Co ores extracted from mines Option 2 : from Ni, Co recycled from Li-ion batteries
Data collection:
Option 1: Based on published data: www.informine.com; www.oee.nrcan.gc.ca and www.nickelinstitute.org
Option 2: based on Umicore information
Functional unit: production of 1 of these cells
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Conclusions SAFTLess environmental impacts when LiCoO2 is produced from recycled Li-ion batteries
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LCA on Prius NiMH battery by Oeko instituteGoal & scope: The general objectives of the LCA study are: To investigate the impact of nickel in rechargeable batteries, To identify the key environmental parameters influenced by the production, the use and the end of life; To identify areas for possible improvements To compare the net impact of driving a Prius vs. a conventional car.
Selected impact categories: Global Warming Potential Acidification Potential (air, water, soil) Eutrophication Potential Photochemical Ozone Creation Potential Use of non-renewable energy carriers Ozone depletion potential Depletion of mineral resources
Review: EMPA, Switzerland
Functional unit: production of 1 Prius pack + 150000 km use phase
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LCA on Prius NiMH battery: impact of recycling
In order to assess the impact of recyling (Umicore process) on the production & use phaze, three scenarios are compared:
Scenario maximum battery collection and recycling: This scenario is designed to show the maximum effect of recycling. It implies a collection rate of 99 % and a transfer of all collected batteries to Umicore.
Scenario 50 % battery collection and recycling: This scenario implies a collection rate of 50 % and a transfer of all collected batteries to Umicore.
Scenario no battery collection and recycling
Following slides: only effect of recycling (0%, 50% or 100 %) is illustrated! Effects of use phase (hybrid driving versus
conventional driving): available on request.
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LCA on Prius NiMH battery: conclusions for recycling Global Warming Potential (GWP) and non-renewable energy carriers: limited impact thanks to recycling because main GWP saving is realized during use phase, not during production and recycling phase
Ozone depletion: main source of zone depletion is production of PTFE (battery compound). As this is not recycled in Umicore’s process, no positive impact.
For all other selected impact parameters: excellent results
Without recycling, Acidification and Eutrophication would be ‘negative’ for NiMH driving (= worse compared to conventional car): primary Ni production releases SO2 and NOx in nature; fully neutral if recycled Ni is used
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LCA on Prius NiMH battery: detailed results
-
2,0
4,0
6,0
8,0
10,0
12,0
14,0
16,0
kg SO2-eq 11,4 6 1 3,2 14,6 9,5 4,4
battery - no collection
battery - 50 % collection
battery - maximum collection
additional components
Total - no battery
collection
Total - 50 % battery
collection
Total - max. battery
collection
66%
30%
100 %
57%
14%
100 %
Acidification potential
Amount of SO2-equivalent produced for 1 functional unit
Impact of non-battery materials, but necessary for a hybrid car (mostly copper, steel, plastics)
Impact of battery materials only
Impact of battery materials + additional materials
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LCA on Prius NiMH battery: detailed results
-
0,2
0,4
0,6
0,8
1,0
1,2
kg PO4-eq 1,0 1 0 0,1 1,1 0,7 0,3
battery - no collection
battery - 50 % collection
battery - maximum collection
additional components
Total - no battery
collection
Total - 50 % battery
collection
Total - max. battery
collection
67 %
33 %
100 %
62 %
24 %
100 %
-
0,05
0,10
0,15
0,20
0,25
kg ethylen-eq 0,11 0,09 0,07 0,08 0,20 0,17 0,15
battery - no collection
battery - 50 % collection
battery - maximum collection
additional components
Total - no battery
collection
Total - 50 % battery
collection
Total - max. battery
collection
88 %
77 %
100 %
80%
60%
100 %
-2,0
-
2,0
4,0
6,0
8,0
10,0
12,0
14,0
16,0
18,0
20,0
kg Ni 17,8 9,7 1,6 -0,0 17,8 9,7 1,6
battery - no collection
battery - 50 % collection
battery - maximum collection
additional components
Total - no battery
collection
Total - 50 % battery
collection
Total - max. battery
collection
55 %
9 %
100 %
55 %
9 %
100 %
Eutrophication Potential
Photochemical Ozone Creation Potential
Depletion of mineral resources
For ‘additional components’, market average recycling schemes are assumed (100 % recycling is supposed as it fits within existing car recycling)
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LCA on mixed oxide Li-ion battery (Ghent University)
Goal & scope:
What resources can be saved through recycling Li-ion batteries? Scenario A: cathode production from recycled Co, Ni (Mn into slag) Scenario B: cathode production from primary (ores) Co, Ni Credits for by-product from recycling were OUT of scope
Impact category:
natural resource consumption
Data acquisition:
Umicore for cathode production and recycling
Eramet, Xstrata
Eco-invent
Calculation method
In order to aggregate use of energy and materials in one figure, a unique quantifier is used: exergy; it is expressed in Joule
Review: EMPA, Switzerland
Functional unit: production of 1 kg of active cathode material (MNC-type)
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LCA on mixed oxide Li-ion battery: Results
0
100
200
300
400
500
600
700
800
900
Ni and Corecycled
Ni and Co fromores
transport
cathodeproduction
precursorproduction
CoSO4
NiSO4
MnSO4
Saving of 51 % natural resources mainly due to:
• eliminating high demanding Ni/CoSO4 from primary resources
• moderate demand of recycling in comparison with high demand of cathode production stages
• Mn is not considered as recycled (in slag, used as concrete additive)
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Improved Umicore Battery Recycling process
Old UBR process uses cokes for technical reasons;
New UBR process no cokes
energy used and CO2 produced in new process: +/- 90 % below old process
CO2 produced for 1 ton batteries recycling
0
500
1000
1500
2000
2500
3000
Old UBR New UBR
un
its
CO
2 Electricity
Natural gas
Oxygen
Cokes
Energy consumed for 1 ton batteries recycling
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
Old UBR New UBR
Electricity
Natural gas
Oxygen
Cokes
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Conclusions
EV-battery recycling is technically feasible, beneficial for the environment and is imposed by law.
The installed battery recycling capacity can cope with growing EV-market
LCA is a powerful tool to assess the environmental impact of recycling processes; it helps to make environmentally sound decisions
In order to optimize the use of LCA, some guidelines should be developed to have a uniform LCA approach:
To compare processes and technologies To compare business models To compare performance To set targets