Processes for separating and recycling battery and electrochemical cell materials are disclosed.

A crushing method for galvanic cells with high energy densities in which mixture of used cells is placed inside an insulated container and carbon dioxide as dry ice is added to this mixture as a cooling medium. Dry ice is added to the mixture of used galvanic cells at a volumetric ration of 0.5:1 to 2:1. The mixture of used cells with dry ice is cooled down from −20° C. to −50° C. and is subsequently fed to the crushing device and subjected to crushing. A stream of used galvanic cells and a stream of dry ice granules are preferably fed simultaneously to the insulated container of the crushing device, and this mixture is forwarded to the working part of the crushing device. At the end of galvanic cell crushing, the mixture of air and gaseous carbon dioxide is returned to the insulated container.

A crushing method for galvanic cells with high energy densities in which mixture of used cells is placed inside an insulated container and carbon dioxide as dry ice is added to this mixture as a cooling medium. Dry ice is added to the mixture of used galvanic cells at a volumetric ration of 0.5:1 to 2:1. The mixture of used cells with dry ice is cooled down from −20° C. to −50° C. and is subsequently fed to the crushing device and subjected to crushing. A stream of used galvanic cells and a stream of dry ice granules are preferably fed simultaneously to the insulated container of the crushing device, and this mixture is forwarded to the working part of the crushing device. At the end of galvanic cell crushing, the mixture of air and gaseous carbon dioxide is returned to the insulated container.

A method is provided for recycling lithium-ion batteries containing plastics, electrolyte, carbon, metals, and lithium. The method includes: Lithium-ion batteries are ground to form ground battery material which is then pyrolyzed at a temperature between about 100° C. and 700° C. for a time sufficient to vaporize about 80 wt % to 100 wt % of electrolytes present in the ground battery material. The resulting material is further ground and screen classified to produce a screen oversize and a screen undersize. The screen oversize comprises metals and plastics, while the screen undersize comprises a black mass material. Lithium dissolution, triboelectric charging and electrostatic separation of the black mass material (not necessarily in that order) produces a liquid comprising dissolved lithium, a graphite product, and a concentrated metal fines product. Lithium is precipitated from the liquid comprising dissolved lithium, and the concentrated metal fines can be further treated by hydrometallurgy or pyrometallurgy processes.

A variety of systems, methods and compositions are disclosed, including, in one method for recycling a spent alkaline battery comprising: dissolving insoluble metal ions in aqueous solution thereby producing pregnant leach solution; extracting zinc sulfate from aqueous solution thereby producing zinc sulfate product and raffinate solution comprising manganese sulfate and potassium sulfate; separating manganese hydroxide from raffinate solution thereby producing manganese sulfate product and aqueous potassium sulfate solution; crystallizing aqueous potassium sulfate solution to produce solid potassium sulfate product. A system for recycling spent alkaline battery comprising: first liquid-solid extraction unit capable of dissolving insoluble metal ions in aqueous solution thereby producing pregnant leach solution; liquid-liquid extraction unit capable of extracting zinc from pregnant leach solution; second liquid-solid extraction unit capable of precipitating manganese hydroxide from raffinate produced by liquid-liquid extraction unit; and third liquid-solid extraction unit capable of crystallizing aqueous potassium sulfate solution produced by second liquid-solid extraction unit.

A variety of systems, methods and compositions are disclosed, including, in one method for recycling a spent alkaline battery comprising: dissolving insoluble metal ions in aqueous solution thereby producing pregnant leach solution; extracting zinc sulfate from aqueous solution thereby producing zinc sulfate product and raffinate solution comprising manganese sulfate and potassium sulfate; separating manganese hydroxide from raffinate solution thereby producing manganese sulfate product and aqueous potassium sulfate solution; crystallizing aqueous potassium sulfate solution to produce solid potassium sulfate product. A system for recycling spent alkaline battery comprising: first liquid-solid extraction unit capable of dissolving insoluble metal ions in aqueous solution thereby producing pregnant leach solution; liquid-liquid extraction unit capable of extracting zinc from pregnant leach solution; second liquid-solid extraction unit capable of precipitating manganese hydroxide from raffinate produced by liquid-liquid extraction unit; and third liquid-solid extraction unit capable of crystallizing aqueous potassium sulfate solution produced by second liquid-solid extraction unit.

Disclosed is a method for anaerobically cracking a power battery, which includes the following steps: disassembling a waste power battery to obtain a battery cell; taking out a diaphragm from the battery cell for later use, and pyrolyzing the battery cell to obtain electrode powder; extracting nickel, cobalt and manganese elements from the electrode powder with an extraction buffer, filtering, taking the filtrate, then adjusting the filtrate with a nickel solution, a cobalt solution and a manganese solution to obtain a solution A, adding the solution A dropwise into ammonium hydroxide under stirring, and then adding an alkali solution under stirring to obtain a solution B; subjecting the solution B to a hydrothermal reaction, filtering, and roasting to obtain a catalyst, such that a chemical formula of the catalyst is Ni.sup.2+.sub.1-x-yCo.sup.2+.sub.xMn.sup.2+.sub.yO, where 0.25≤x<0.45, 0.25≤y<0.45.

Embodiments described herein relate generally to methods for the remediation of electrochemical cell electrodes. In some embodiments, a method includes obtaining an electrode material. At least a portion of the electrode material is rinsed to remove a residue therefrom. The electrode material is separated into constituents for reuse.

Embodiments described herein relate generally to methods for the remediation of electrochemical cell electrodes. In some embodiments, a method includes obtaining an electrode material. At least a portion of the electrode material is rinsed to remove a residue therefrom. The electrode material is separated into constituents for reuse.

A biodegradable solid aqueous electrolyte composition, an electrochemical device incorporating the electrolyte composition, and methods for the same are provided. The electrolyte composition may include a rubber-like hydrogel including a copolymer and a salt. The copolymer may include at least two polycaprolactone chains coupled with a polymeric center block. The polymeric center block may include polyvinyl alcohol. The hydrogel may be biodegradable. The electrochemical device may include an anode, a cathode, and the electrolyte composition disposed between the anode and the cathode.