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

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Key megatrends for Umicore

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· More stringent emission control

· Resource scarcity

· Renewable energy · Electrification of the automobile

Umicore fit with megatrends

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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

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“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

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Types of batteries

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Laptop batteries

Mobile phone batteries

HEV-PHEV-EV batteries

Types of batteries

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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

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· More stringent emission control

· Resource scarcity

· Renewable energy · Electrification of the automobile

Legislative framework

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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

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Closing the loop

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material

solutionsMetals

Application

know-how

Recycling

Material

solutions

Chemistry

Material science

Metallurgy

Closing the battery loop

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Battery recycling flowsheet

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Battery recycling flowsheet

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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

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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

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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

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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

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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.

Thank you for your attention!