# US 2022/0223379 A1 · Methods and systems for reclamation of li-ion cathode materials using microwave plasma processing

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- Number: US 2022/0223379 A1
- Document ID: US20220223379A1
- Status: Published application
- Kind: A1
- Application number: 17/647,422
- Filed: 2022-01-07
- Published: 2022-07-14
- Earliest claimed: 2021-01-11
- Assignees: 6K Inc.
- Applicants: 6K Inc.
- Inventors: Richard K. Holman; Gregory M. Wrobel
- Web page: https://patentgrep.com/patent/US20220223379A1

## CPC

- H01J 37/32201: {Generating means}
- C01G 53/502: containing lithium and cobalt
- C01G 53/504: with the molar ratio of nickel with respect to all the metals other than alkali metals higher than or equal to 0.5, e.g. Li(MzNixCoyMn1-x-y-z)O2 with x ≥ 0.5
- C01G 53/506: with the molar ratio of nickel with respect to all the metals other than alkali metals higher than or equal to 0.8, e.g. Li(MzNixCoyMn1-x-y-z)O2 with x ≥ 0.8
- H01J 37/3255: {Material}
- H01M 4/131: Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
- H01M 4/1391: of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
- H01M 4/505: of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
- H01M 4/525: of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H05H 1/4622: {using waveguides}
- H01J 2237/0817: Microwaves
- Y02P 10/20: Recycling
- Y02W 30/84: Recycling of batteries or fuel cells
- H01J: ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS (spark-gaps H01T; electric arc lamps H05B31/00; particle accelerators H05H)
- C01G: COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F (metal hydrides {monoborane, diborane or addition complexes thereof} C01B6/00; salts of oxyacids of halogens C01B11/00; peroxides, salts or peroxyacids C01B15/00; thiosulfates, dithionites, polythionates C01B17/64; compounds containing selenium, or tellurium C01B19/00; binary compounds of nitrogen with metals C01B21/06; azides C01B21/08; {compounds containing nitrogen, other non-metals and metal C01B21/082}; metal amides C01B21/092; nitrites C01B21/50; {compounds of noble gases C01B23/0005}; phosphides C01B25/08; salts of oxyacids of phosphorus C01B25/16; carbides C01B32/90; compounds containing silicon C01B33/00; compounds containing boron C01B35/00; compounds having molecular sieve properties but not having base-exchange properties C01B37/00; compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites, C01B39/00; cyanides C01C3/08; salts of cyanamide C01C3/16; thiocyanates C01C3/20)
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H05H: PLASMA TECHNIQUE (apparatus or processes specially adapted for producing X-rays H05G2/00); PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

Disclosed herein are embodiments of systems and methods for recycling used solid feedstocks containing lithium powders for use in lithium-ion batteries. The used solid feedstocks may be Lithium Nickel Manganese Cobalt Oxide (NMC) materials. In some embodiments, the used solid feedstock can undergo a microwave plasma process to produce a newly usable, lithium supplemented solid precursor with augmented chemistries and physical properties.

## Claims

### Claim 1

A method for synthesizing lithium nickel manganese cobalt oxide (NMC) powder in a microwave plasma apparatus, the method comprising:
providing a feedstock to the microwave plasma apparatus, the feedstock comprising end-of-life NMC powder, the end-of-life NMC powder having an average nickel to cobalt ratio of 5:2 or less; and
introducing the feedstock into a microwave-generated plasma of the microwave plasma apparatus to synthesize an NMC powder having an average nickel to cobalt ratio greater than 5:2.

### Claim 2 (depends on 1)

The method of claim 1, further comprising introducing nickel containing material, manganese containing material, or cobalt containing material into the microwave-generated plasma concurrently with introducing the feedstock into the microwave-generated plasma.

### Claim 3 (depends on 1)

The method of claim 1, wherein a microstructure of the end-of-life NMC powder comprises one or more imperfections, cracks, or fissures, and wherein introducing the feedstock into the microwave-generated plasma melts the end-of-life NMC powder.

### Claim 4 (depends on 3)

The method of claim 3, wherein a microstructure of the synthesized NMC powder does not comprise the one or more imperfections, cracks, or fissures.

### Claim 5 (depends on 1)

The method of claim 1, further comprising introducing lithium (Li) containing material into the microwave-generated plasma concurrently introducing the feedstock into the microwave-generated plasma.

### Claim 6 (depends on 1)

The method of claim 1, wherein the end-of-life NMC powder comprises NMC-532 or NMC-111.

### Claim 7 (depends on 1)

The method of claim 1, further comprising adding lithium (Li) containing material to the feedstock prior to introducing the feedstock into the microwave-generated plasma.

### Claim 8 (depends on 1)

The method of claim 1, wherein the end-of-life NMC powder is obtained from a used lithium-ion battery.

### Claim 9

A method for synthesizing lithium nickel manganese cobalt oxide (NMC) powder in a microwave plasma apparatus, the method comprising:
providing a feedstock to the microwave plasma apparatus, the feedstock comprising end-of-life NMC powder, the end-of-life NMC powder and having an average nickel to cobalt ratio of 5:2 or less; and
introducing the end-of-life NMC powder into a microwave-generated plasma of the microwave plasma apparatus to synthesize an NMC powder,
wherein the end-of-life NMC powder is not reduced to its constituent elements prior to introducing the end-of-life NMC powder into the microwave-generated plasma.

### Claim 10 (depends on 9)

The method of claim 9, further comprising introducing nickel containing material into the microwave-generated plasma concurrently with introducing the feedstock into the microwave-generated plasma.

### Claim 11 (depends on 9)

The method of claim 9, wherein a microstructure of the end-of-life NMC powder comprises one or more imperfections, cracks, or fissures, and wherein introducing the feedstock into the microwave-generated plasma melts the end-of-life NMC powder.

### Claim 12 (depends on 11)

The method of claim 11, wherein a microstructure of the synthesized NMC powder does not comprise the one or more imperfections, cracks, or fissures.

### Claim 13 (depends on 9)

The method of claim 9, further comprising introducing lithium (Li) containing material into the microwave-generated plasma concurrently introducing the feedstock into the microwave-generated plasma.

### Claim 14 (depends on 9)

The method of claim 9, wherein the end-of-life NMC powder comprises NMC-532 or NMC-111.

### Claim 15 (depends on 9)

The method of claim 9, further comprising adding lithium (Li) containing material to the feedstock prior to introducing the feedstock into the microwave-generated plasma.

### Claim 16 (depends on 9)

The method of claim 9, wherein the end-of-life NMC powder is obtained from a used lithium-ion battery.

### Claim 17

A lithium nickel manganese cobalt oxide (NMC) powder produced by a method comprising:
providing a feedstock to a microwave plasma apparatus, the feedstock comprising end-of-life NMC powder, the end-of-life NMC powder having an average nickel to cobalt ratio of 5:2 or less; and
introducing the feedstock into a microwave-generated plasma of the microwave plasma apparatus to synthesize an NMC powder or an NMC precursor having an average nickel to cobalt ratio greater than 5:2.

### Claim 18 (depends on 17)

The NMC powder of claim 17, wherein the end-of-life NMC powder comprises NMC-111, NMC-442, or NMC-532

### Claim 19 (depends on 17)

The NMC powder of claim 17, wherein the NMC powder or the NMC precursor comprises NMC-611, NMC-811, or NMC-9.5.5.

### Claim 20 (depends on 17)

The NMC powder of claim 17, wherein the NMC powder or the NMC precursor has an average nickel to cobalt ratio of 5:2, 6:1, 8:1, or 18:1.