Document zzed48KGp4mpr1Y1awERoB4pn

2008 Technology demonstration project for CO2-saving recycling and other equipment. (Demonstration project for a low-carbon recycling system for used lithium-ion batteries for automotive and other applications). (written) report 28 February 2019 Taiheiyo Cement Corporation Table of Contents 1. Implementation of demonstration projects .................................................................... 1 1.1 Outline of the demonstration project...................................................................................... 1 1.1.1 Objectives, background, issues, etc..................................................................................... 1 1.1.2 Implementation system.......................................................................................................... 3 1.1.3 System of demonstration projects......................................................................................... 4 1.1.4 Implementation flow of the demonstration project ............................................................... 5 1.2 Results of demonstration projects......................................................................................... 8 1.2.1 Experiments on separation and manual dismantling of used LIBs .................................... 8 1.2.2 Experimental roasting of spent LIBs .................................................................................. 10 1.2.3 Experiments in resource recovery from roasting and burning materials......................... 18 1.3 Overall design of treatment and recycling schemes......................................................... 23 2. Verification of environmental impact reduction benefits. ......................................... 24 2.1 Examination of the effects of resource recycling................................................................ 24 2.2 Study of the effect of reducing CO ...................................................................................... 25 2.3 Study of CO2 emissions from the collection of used LIB packs.................................... 35 2.4 Study on the effect of reducing environmental impact due to exhaust emissions......... 37 3. Verification of project feasibility through economic feasibility assessment ........ 38 3.1 Economic evaluation of used LIB packs under the project scheme. ............................... 38 3.2 Verification of the possibility of improving the economic efficiency of used LIB packs by reviewing and improving the project scheme40 3.3 Model studies to reduce transport costs ............................................................................ 41 4. Business feasibility of this treatment technology ...................................................... 42 4.1 Forecasted market size of waste to be received............................................................... 42 4.2 Horizontal expansion to its own existing facilities.............................................................. 44 4.3 Advantages of the Project. ................................................................................................. 45 5. Future challenges and business plans ............................................................................ 47 5.1 Future tasks.......................................................................................................................... 47 5.2 Future business plans ......................................................................................................... 47 6. generalise ................................................................................................................................ 48 Figure Table of contents Figure 1-1. .............................................................................................................................. Objectives, background and issues of this demonstration project................................................ 2 Figure 1-2. .............................................................................................................................. Implementation structure diagram..................................................................................................... 3 Figure 1-3. .............................................................................................................................. System of the project ........................................................................................................................... 4 Figure 1-4. .............................................................................................................................. Overview of the implementation of this demonstration project........................................................ 5 Figure 1-5 Disassembly and manual disassembly of ...............................................................used LIB packs in this demonstration project ............................................................................................ 6 Figure 1-6. .............................................................................................................................. Roasting furnace in this demonstration project (Tsuruga Cement) .............................................. 6 Figure 1-7. .............................................................................................................................. Roasting furnace in this demonstration project (Hiroshima Gas Techno Service) ..................... 7 Figure 1-8. .............................................................................................................................. Crushing and sorting equipment in this demonstration project....................................................... 7 Figure 1-9. ............................................................................................................................ Distribution of recovered resources by roasting temperature and roasting time....................... 11 Figure 1-10 Kerosene consumption per unit module volume by level....................................... 12 Figure 1-11 Temperature inside the basket with and without discharge................................... 14 Figure 1-12........................................................................................................................... Percentage distribution of recovered resources by LIB module type........................................... 16 Figure 1-13........................................................................................................................... Material balance of recovered metals by LIB module type ........................................................... 18 Figure 1-14 Overall design of treatment and recycling schemes............................................... 23 Figure 1-15 Design and operational approach for a low-carbon system using an adjacent cement kiln. .................................................................................................................................................... 23 Figure 2-1. ............................................................................................................................ Baseline process (stationary furnace treatment).......................................................................... 25 Figure 2-2. ............................................................................................................................ Recycling process of this demonstration project ........................................................................... 25 Figure 2-3. ............................................................................................................................ Comparison of CO2 emissions per tonne by LIB pack..................................................................... 26 Figure 2-4. ............................................................................................................................ Comparison of CO2 emissions per unit of annual throughput by LIB pack...................................... 26 Figure 2-5. ............................................................................................................................ Model to study CO2 emissions from the collection of used LIB packs ....................................................... 35 Figure 2-6. ............................................................................................................................ CO2 emissions from the collection of used LIB packs ............................................................................... 35 Figure 2-7. ............................................................................................................................ Material balance of fluorine in the project....................................................................................... 37 Figure 3-1. ............................................................................................................................ Conveyance patterns in the economic evaluation study of the project ....................................... 40 Figure 3-2. ............................................................................................................................ Model for reducing transport costs in the project ..................................................................................... 41 Figure 4-1 Projected disposal of automotive LIBs .................................................................................................................. 42 Figure 4-2 Market size forecast for stationary LIBs .................................................................................................................... 43 Figure 4-3. ............................................................................................................................ Pacific Cement's cement business locations in Japan .................................................................. 44 Figure 5-1. ............................................................................................................................ Schedule for the future....................................................................................................................... 47 Table Table of contents Table 1-1......................................................................... Breakdown of samples used (in pcs) 8 Table 1-2.............................................. Material balance and residual voltage etc. in LIB packs 9 Table 1-3............................................ Verification items in the roasting process of LIB modules 10 Table 1-4 Amount of lithium per tonne of LIB module by ....................level (distribution ratio) 11 Table 1-5................................................................................. Kerosene consumption by level 12 Table 1-6. ............................................................................... Kerosene consumption per input 13 Table 1-7 Photographs of LIB module roasting experiments with .............and without discharge 14 Table 1-8. .................................................... Kerosene consumption by presence of discharge 15 Table 1-9 Photographs of ...............................................spent LIB modules submerged in water 15 Table 1-10. ............... Kerosene consumption by LIB module type and in continuous operation 16 Table 1-11. .............. Lithium distribution rates by LIB module type and in continuous operation 17 Table 1-12. Photographs of roasting and recovered material after crushing and sorting by roasting temperature and roasting time ....................................................................................................... 19 Table 1-13. Photographs of roasted LIB modules by type and recovered material after crushing and sorting ....................................................................................................................................... 21 Table 2-1........................... Results of the evaluation of resource recycling effects of the project 24 Table 2-2............. Results of evaluation of resource recycling effects in H29 projects (indicative) 24 Table 2-3. CO2 emission reductions compared to the project and stationary furnace treatment (per tonne of LIB pack).................................................................................................................... 27 Table 2-4. CO2 emission reductions compared to the project and stationary furnace treatment (per year of treatment).................................................................................................................. 27 Table 2-5 Activity and CO2 emissions intensity of stationary furnace treatment (per tonne of 2 (domestic) LIB packs for on-board use) . ................................................................................................................................................. 28 Table 2-6 Activity and CO2 emissions intensity of stationary furnace treatment (per tonne of vehicle-mounted 4 (domestic) LIB packs) . ................................................................................................................................................. 29 Table 2-7 Activity and CO2 emissions intensity of stationary furnace treatment (per tonne of mixed (multi-species) LIB packs) . ................................................................................................................................................. 30 Table 2-8 ................................................Activity volume and CO2 emissions intensity of the project (per tonne of 2 (domestic) LIB packs for on-board use) ................................... 31 Table 2-9 ................................................Activity volume and CO2 emissions intensity of the project (per tonne of vehicle-mounted 4 (domestic) LIB packs) ................................... 32 Table 2-10 ......................................................Activities and CO2 emissions intensity of the project (per tonne of mixed (multi-species) LIB packs) ............................................... 33 Table 2-11. ................................. List of sources of emission factors used in the estimation of CO 34 Table 2-12..................... Basis for calculation of CO2 emissions from collection of used LIB packs 36 Table 3-1 Overall economic evaluation of spent LIB modules by type of resource value and cost 38 Table 3-2 Breakdown of total costs in .....................................spent LIB pack disposal schemes 39 Table 3-3 Comparison of the composition of ...................................................used LIB packs in this year and last year and overall assessment of income and expenditure........... 39 3-4 LIB . 40 Table 3-5 Comparison of ..................................................area image and cost of transporting used LIB packs by ..........................................................................transport condition 41 Table 4-1................................... Advantages and disadvantages of different treatment systems 45 List of a b b r e v i a t i o n s In this report, the following abbreviations are used to unify the abbreviations. abbreviation Notation in this report. LIB hr. formal name Lithium-ion Rechargeable Battery hour Meani ng etc. lithium-ion rechargeable battery Hours. (Summary) 1. Background and issues The project aims to demonstrate a low-carbon recycling system for used lithium-ion batteries ('LIBs'). The technological development of recycling processes that has been pursued so far has mainly targeted small LIBs and has lagged behind in addressing large LIB packs/modules. However, with the spread of next-generation vehicles, there is now a need to develop recycling technologies for large LIB packs and modules. Large LIB packs are dismantled and processed in the form of LIB modules after removing the exterior base metal, etc. Heat treatment is essential as direct crushing of LIB modules risks ignition, leading to plant accidents. However, heat treatment requires a large amount of energy, and the recovery of rare metals such as lithium, cobalt and nickel contained in the LIB modules is problematic. At present, electric furnaces and stationary furnaces are available as treatment methods for LIB modules, but in electric furnaces, only iron is recycled and other base metals and rare metals are not recovered, while in stationary furnaces, base metals and rare metals are recovered, but they are in an oxidised state at high temperatures, so there are issues with their integrity. There are three main recycling issues to be resolved for used large LIB packs (i) Low-carbon ... Development of systems that enable the reduction of energy consumption in the heat treatment process. (ii) Resource recycling ... Development of processing technology for highly efficient recovery of metal resources (rare metals and base metals such as lithium) by material. (iii) Improvement of other environmental impacts.. . Development of a low- cost detoxification system for hydrogen fluoride gas generated in the heat treatment of LIB modules. 2. Objectives and implementation of the project With the aim of recycling used large LIB packs in a low-carbon treatment scheme, this demonstration project will continue from the previous year to conduct demonstration experiments to recover high-grade metal resources from large LIB packs and modules using a roasting furnace. The treatment targets are a wide variety of large LIB packs and modules for automotive, stationary and other applications. The objectives of the project are as follows. Low carbon ... Design of a system in which the roasting furnace is located next to the cement calcination furnace and the waste heat from the cement calcination process is u s e d t o reduce the energy consumption of the LIB roasting process. (ii) Resource recycling ... Verification of roasting conditions that do not oxidise metal resources (rare metals andbase metals such as lithium)and recover each metal i resource in high concentration. (iii) Other environmental impact improvements ... Design of a low-cost detoxification system for hydrogen fluoride gas generated in the heat treatment of LIB modules, using an adjacent cement calcination furnace. As the number of types of LIB packs used in the demonstration was small last year, the number of types to be used this year will be increased. The number of roasters will be increased and the roasting conditions will be verified under conditions close to those in actual operation. In addition, the roasting temperature and time will be increased from the previous year in order to study roasting conditions that enable more efficient recovery of lithium compounds as a solution to the problems of the previous year. ii In addition to verifying the kerosene consumption by setting up a more detailed specification, verifying the kerosene consumption with and without input and residual power, and mass processing in continuous operation for practical use, the issues to be improved will be identified and sorted out. By adjusting the roasting temperature, only the combustible content and adhesives are burnt, while preventing melting and oxidation of the metal, facilitating the recovery of metal resources. By crushing and sorting the roasted LIB modules, not only base metals but also rare metals such as lithium are concentrated to a recoverable concentration for metal recycling. In addition, the waste heat from the cement calcination process is effectively utilised to save energy, and by utilising existing waste treatment know-how, the aim is to build a treatment system that enables the recycling of all large LIB packs and modules at a lower cost than other technologies. 3. Results of the demonstration project The implementation details and main results of this demonstration project are described below. The used large LIB packs and modules used in the verification experiment were vehicle-mounted LIB packs from domestic and foreign automobile manufacturers and stationary LIB modules from domestic battery manufacturers. (i ) Separation and manual dismantling of used LIBs With the aim of reducing the amount of roasting treatment and recovering base metal and plastic resources, used LIB packs were collected, sorted and dismantled by hand, and the amount of resources recovered was measured. Note that manual dismantling was only carried out for vehicle-mounted LIBs discharged as packs, but not for stationary LIBs discharged as modules. The results of the manual dismantling showed that the LIB packs used this year had a higher weight ratio of modules to packs than those used last year, and that the composition ratio of ferrous, non-ferrous and plastic was different for each LIB pack. Roasting of spent LIBs Comparative verification of the roasting temperature range and heating time showed that the combination of 500C - 4 hours had the highest recovery of base and rare metals, as well as the best lithium distribution to recovered material less than 1 mm, and also used the least amount of paraffin per unit. A comparison of kerosene consumption by input volume confirms that the higher the input volume, the less paraffin is used per input volume. Regarding the effect of residual power on roasting, a comparison of kerosene consumption with and without discharge of the LIB module showed that kerosene consumption per unit was lower without discharge. This could be due to the contribution of residual power as fuel. In the case where a large number of various LIB modules were mixed and roasted in continuous operation, the base metal was recovered at a high efficiency as targeted, but the rare metal recovery rate was approximately 50%, the same as in the previous year. When compared to the case where multiple types of LIB modules were roasted individually, iii the recovery rate varied, which led to the finding that the recovery rate of rare metals differs depending on the LIB module. The behaviour of lithium, including in the flue gas, was also checked and it was confirmed that lithium was not distributed in the flue gas at any input level. (iii) Crushing and sorting of roasted LIBs Highly efficient recovery of base metal and pole powder (<1 mm) containing lithium and other elements from roasted materials. iv Therefore, shear crushing was followed by sieve sorting. Metal analysis was carried out on the recovered electrode powder less than 1 mm and on the recovered material of 1 mm or more to check the material balance of the metal resources contained in the LIB module, and found that more than 80% of the lithium could be recovered in the electrode powder, depending on the input level. (iv) Overall design of the treatment scheme. Based on the results of the demonstration tests, the overall design of the recycling process for used LIB packs was carried out and the material balance of the recycling flow was calculated. In the treatment flow of used LIB packs, LIBs in pack form are dismantled by hand, the base metal and plastic are recovered, the LIBs are made into modules and then roasted. The roasted materials are crushed by shearing and sieved, and the recovered electrode powder of less than 1 mm is recycled as rare metals such as lithium, while the recovered materials of 1 mm or more are recycled as copper. The scale of the treatment scheme was calculated to be around 4,600 t/year of spent LIB packs to be treated, based on a roasting throughput of 3,000 t/year (10 t/day), and the resources to be recovered to be 744 t/year of polar powder and 3,140 t/year of base metals in total. With regard to energy saving effects, as per last year's design, the annual kerosene consumption in the roasting furnace is expected to be reduced by about 30% by utilising the exhaust heat from the cement calcination process, and the combustible exhaust gas generated from the roasting furnace will be used effectively in the cement calcination process, replacing about 0.1% of the coal required for cement production. The project is expected to replace approximately 0.1% of the coal required for cement production. 4. Environmental improvement effects In the calculation of the carbon dioxide reduction effect of the project scheme, the technology to be compared was set to incineration in a stationary furnace. As it was difficult to obtain data relating to the energy consumption of the treatment processes before and after incineration in stationary furnaces, the hydrogen fluoride treatment process was excluded from the scope of calculation, as it was assumed to be identical to the project as a more conservative calculation. For the recycling effect, only the amount of resources actually assessed was included in the calculation. The results of the estimation showed that the carbon dioxide reduction effect of processing a mixture of various types of LIB packs was 434 kg-CO2/LIB pack. Based on the results of this year's demonstration, it is expected that the amount of kerosene used can be reduced to a lower level than in the previous year, resulting in a greater reduction effect. For a processing scale of 3,000 t/year of roasting, the carbon dioxide reduction effect was calculated to be 1,986 t-CO2/year. The actual resource recycling effect of the assessed resource volume only was calculated to be between 30% and 40%. The decrease from the previous year is thought to be due to the different amounts of ferrous and non-ferrous materials that make up the LIB packs. It was v found that the resource recovery rate of LIB p a c k s d e p e n d s o n t h e content of the constituent materials, but as the recovered materials that are not evaluated as metal are recycled by cement recycling, the amount of landfill disposal for any LIB packs i s zero and therefore the recycling rate in this recycling system is 100%. The behaviour of halogen elements (fluorine) inLIB packs was verified for the low-cost detoxification of exhaust gases (containing hydrogen fluoride): more than 80% of the halogen elements (fluorine) in all LIB packs were distributed in the polar powder less than 1 mm. The remainder was distributed in the roasting exhaust gas, which is sent to a cement calcination furnace for detoxification. Measurements of the final flue gas from the cement production plant confirmed the detoxification treatment of fluorine. vi 5. economic evaluation A comprehensive assessment of the economics of LIB pack processing in the project was carried out by calculating the valorisation of the recovered resources and the costs of transport and treatment facilities, labour costs, consumables costs, etc. The valorisation of the rare metals among the recovered resources was based on the concentration of the recovered material; any recovered material larger than 1 mm was considered to be copper valued. The results of the estimation showed that the costs of all LIB packs were higher than the resource assessment, and the overall assessment was calculated to be around -JPY 150,000/t. The reason for the cost increase over the previous year is thought to be due to the different material composition of the LIB packs. The cost of LIB packs increased overall due to an increase in the costs of transporting and roasting LIB modules, especially when the amount of base metal in the LIB packs decreased and the amount of LIB modules increased. The cost of LIB packs differs depending on the material composition, and we would like to reflect this in the cost setting for actual operation. In order to reduce costs, the company considered cost reduction through more efficient transport and mass processing, and decided to set up a system where roasting, crushing and sorting are carried out at a single location, tripling the processing volume to 30 t/day, which received a comprehensive evaluation. The cost is expected to be reduced to around -100,000/t. As transport costs account for more than 1/3 of the total costs, it will be necessary to consider the consolidation and scaling up of treatment facilities as well as the selection of dismantling sites in the future. 6. Future challenges and commercialisation timelines LIB packs have a wide variety of structures and material compositions. As a result of dismantling and roasting a wide variety of LIB packs in this project, it became clear that the resource recovery rate and the cost of treatment differ greatly depending on the material composition of each LIB pack. These findings will be utilised in actual operations, for example by adjusting roasting conditions to increase the resource recovery rate. In addition, it is necessary to improve the structure of the packing and handling equipment and baskets used in the collection, manual dismantling, roasting, crushing and sorting processes in order to make them more efficient and labour-saving in practical use. The schedule for the future is to establish a mass treatment system from 2019, to save labour for input and discharge, to obtain permits for demonstration facilities, etc., and to commercialise the system from 2021. vii Summary Executive Summary 1. Backgrounds and challenges This project aims to demonstrate a low-carbon recycling system for used lithium-ion rechargeable batteries (hereinafter abbreviated as "LIB"). While the development of recycling techniques has been focused on compact lithium-ion batteries, those for large-sized LIB pack modules have yet to be fully developed. With nextgeneration vehicles entering the market, however, there is a growing need to develop recycling techniques for large-sized LIB pack modules. LIB pack modules. Large-sized LIB packs are stripped down to modules, with their exterior (base metals, etc.) removed, for recycling purposes. Such heat treatment, however, requires a massive amount of energy while recovery of rare metals (lithium, lithium alloys, etc.) is required. LIB modules can be heated either in an electric furnace or in a stationary furnace; the former recovers only iron with other base metals and rare metals wasted, whereas the latter recovers them but oxidation at oxidation is difficult. The latter recovers them but oxidation at high temperatures causes quality problems. Challenges in recycling used large-sized LIB packs can be summarised as follows. 1) Low carbon: Development of systems that require less energy for heat treatment. 2) Resource recycling: development of techniques to individually recover metal resources (base metals and rare metals such as lithium) in an efficient manner. 3) Other environmental impact reductions: development of systems that efficiently detoxify hydrogen fluoride gas generated by heating LIB modules. 2. Project objectives and outlines Following last year's demonstrations, this project demonstrates the recovery of high-quality metal resources from large-sized LIB pack The targets are large-sized LIB pack modules for various automobile and stationary use. The targets are large-sized LIB pack modules for various automobile and stationary use. The project objectives are:. 1) Low carbon: Development of systems that reduce energy consumption from roasting processes, with a roasting furnace installed beside a cement kiln to Low carbon: Development of systems that reduce energy consumption from roasting processes, with a roasting furnace installed beside a cement kiln to make use of the waste heat from the latter. 2) Resource recycling: Testing of roasting conditions for recovering each metal resource (base metals and rare metals such as lithium) at high concentrations without oxidising it. 3) Other environmental impact reductions: designing of systems that efficiently detoxify hydrogen fluoride gas generated by heating LIB modules, using a neighboring cement kiln. viii As last year's demonstrations involved limited types of LIB packs, the project deals with a ix Variety of types this year, with roasting conditions tested under near-commercial conditions. roasting temperatures and time, moreover, are adjusted More finely to test roasting conditions so that lithium compounds can be recovered more efficiently - i.e., solutions to last year 's problems - while examining the consumption of kerosene according to the amount of input and with/without the residual electricity, and implementing large-scale continuous treatment for commercialisation purposes, all designed to identify and list what needs to be improved. Roasting temperatures are adjusted to exclusively burn combustibles and adhesives while preventing oxidation of metals without melting, thereby At the same time, roasted LIB modules are crushed and segregated to increase the concentrations of base metals and rare metals such as lithium, which enables their recovery and, by extension, metal recycling. In addition, the waste heat from a cement kiln is used to reduce energy consumption, with existing waste treatment techniques mobilised to develop treatment systems that fully recycle large-sized LIB pack modules at lower costs. 3. Demonstration results The following provides how the demonstrations were conducted and turned out. for automobile use (domestic and foreign made) and LIB modules for stationary use (made by domestic battery manufacturers). 1) Segregation and manual dismantling of used LIBs. Used LIB packs were collected, segregated and manually dismantled, followed by measurement of the amount of recovered resources, to reduce the amount of Only LIB modules for automobile use discarded as packs were manually dismantled, which was not the case with LIBs for stationary use discarded as modules. The results of manual dismantling show that the modules are much heavier than the packs, compared with last year's results, compared with last year's results, compared with last year's results, compared with last year's results. The results of manual dismantling show that the modules are much heavier than the packs, compared with last year's results, while the composition ratio of iron, non-ferrous metals and plastics differs from pack to pack. 2) Roasting of used LIBs The roasting temperature range was compared with the roasting time; base metals and rare metals were recovered most effectively when roasted at 500C for The roasting temperature range was compared with the roasting time; base metals and rare metals were recovered most effectively when roasted at 500C for four hours; the lithium distribution ratio in recovered materials smaller than 1 mm was highest and its consumption of kerosene per unit was lowest. Comparison of kerosene consumption by the amount of input shows that the consumption per input decreases as the input increases. x With respect to the impact of residual electricity on roasting, a comparison of kerosene consumption with/without discharge from LIB modules shows that the consumption per unit xi decreases when there is no discharge, which suggests that residual electricity functions as fuel. Large amounts of various LIB modules were mixed and roasted continuously; base metals were recovered efficiently as originally planned while the Individual roasting of each LIB module, meanwhile, resulted in fluctuations in the recovery rate, which indicates that the recovery rate of rare metals differs from module to module. In addition, the test results of the lithium-ion batteries were recovered efficiently as originally planned while the recovery rate of rare metals remained at about 50% as in the case of last year's demonstrations. In addition, the test results of lithium behaviour in exhaust gas, etc., show that lithium does not exist in exhaust gas at any input level. 3) Crushing and segregation of roasted LIBs Roasted LIBs were shredded, crushed and screened to efficiently recover electrode particles (smaller than 1 mm, containing base metals, lithium, etc.). .). Recovered electrode particles (smaller than 1 mm) and other recovered materials (1 mm or larger) were then analysed to determine the material balance of Recovered electrode particles (smaller than 1 mm) and other recovered materials (1 mm or larger) were then analysed to determine the material balance of metal resources contained in LIB modules; lithium consists of more than 80% of electrode particles at certain input levels. 4) Treatment scheme design On the basis of the demonstration results, the recycling of used LIB packs was designed and the material balance of a recycle flow was calculated. As a treatment flow of used LIB packs, LIBs in the form of packs were manually dismantled into modules, with base metals and plastics recovered, followed by Roasted materials were then shredded, crushed and screened to recover electrode particles (smaller than 1 mm, containing lithium and other Roasted materials were then shredded, crushed and screened to recover electrode particles (smaller than 1 mm, containing lithium and other rare metals) and other materials (1 mm or larger, containing copper). Given that 3,000 tonnes of LIBs are roasted per year (10 tonnes/day), the amount of used LIB packs to be treated is estimated at about 4,600 tonnes/year, which Given that 3 000 tonnes of LIBs are roasted per year (10 tonnes/day), the amount of used LIB packs to be treated is estimated at about 4 600 tonnes/year, which results in a recovery of 744 tonnes/year of electrode particles and 3 140 tonnes/year of base metals. As for the energy-saving effect, the consumption of kerosene for roasting can be reduced by about 30% per year by using waste energy from a cement kiln, as As for the energysaving effect, the consumption of kerosene for roasting can be reduced by about 30% per year by using waste energy from a cement kiln, as designed last year, while about 0.1% of coal used for cement production can be substituted by feeding the combustible exhaust gas from a roasting furnace to a cement kiln. 4. Environmental improvement effect xii Comparison was made with incineration in a stationary furnace to calculate the CO2 reduction effect of the project. As data on the energy consumption of treatment before and after the incineration was hardly available, a conservative estimate was made, where the consumption is considered the same as that As for the recycling effect, only the amount of resources to be evaluated was included in the calculation. As for the recycling effect, only the amount of resources to be evaluated was included in the calculation. The CO2 reduction effect of an integrated treatment of various LIB packs was calculated to xiii The results of this year's demonstrations indicate that the kerosene consumption can be reduced from last year 's levels, which leads to a greater CO2 reduction effect; 1,986 tonnes/year of CO2 can be reduced given that 3,000 tonnes/year of LIBs are roasted . The recycling effect of resources to be evaluated is calculated somewhere between 30% and 40%, which is lower than last year's levels. While the resource recovery rate of LIB packs has proved to be dependent on their component makeup, materials that are not recovered as metals are recycled as cement materials. This means that all LIB packs This means that all LIB packs result in zero landfill, which brings the project's recycling rate to 100%. The behaviour of halogens (fluorine) contained in LIB packs was examined with respect to low-cost detoxification of the exhaust gas containing hydrogen The behaviour of halogens (fluorine) contained in LIB packs was examined with respect to low-cost detoxification of the exhaust gas containing hydrogen fluoride, the results of which indicate that more than 80% of them exists in electrode particles smaller than 1 mm, with the rest distributed in the cement kiln. Incidentally, the detoxification of fluorine was verified through analysis of the exhaust gas from a cement kiln. Incidentally, the detoxification of fluorine was verified through analysis of the exhaust gas from a cement kiln. 5. Cost-effectiveness evaluation The overall cost-effectiveness of the project's LIB pack treatment was evaluated based on the calculation of valuables in recovered Of recovered resources, rare metals were evaluated for their value Of recovered resources, rare metals were evaluated for their value while those equal to or larger than 1 mm were evaluated as copper. As it turns out, the overall cost outweighs the value of recovered resources, with the loss calculated at around 150,000/ton. In particular, a decrease in the amount of base metals in LIB packs and an increase in the In particular, a decrease in the amount of base metals in LIB packs and an increase in the amount of LIB modules boosts the costs of LIB module transportation, roasting, etc., which results in a higher overall cost. The makeup of components differs from pack to pack and so does the cost, which will be reflected in the calculation of commercial operation costs. The makeup of components differs from pack to pack and so does the cost, which will be reflected in the calculation of commercial operation costs. Cost reduction measures such as streamlined transportation and a high-volume treatment were therefore reviewed; centralised crushing and As the transportation cost accounts for more than one-third of the overall cost, treatment facilities should be centralised and expanded, and dismantling centres were therefore reviewed; centralised crushing and segregation, and a treatment of 30 tons/day (three times the current level) would reduce the loss to around 100,000/ton. As the transportation cost accounts for more than one-third of the overall cost, treatment facilities should be centralised and expanded, and dismantling centres should be located properly. 6. Challenges to be addressed and the commercialisation timeline xiv The structure and component makeup of LIB packs differ significantly from pack to pack. Meanwhile, show that the resource recovery rate and treatment cost fluctuate significantly due to differences in the component makeup of LIB packs. These findings will be taken into account in implementing commercial operations while roasting conditions will be adjusted to increase the recovery rate. These findings will be taken into account in implementing commercial operations while roasting conditions will be adjusted to increase the recovery rate. xv In addition, improvements should be made in packing styles for procurement, manual dismantling, roasting, crushing and segregation, and in the In addition improvements should be made in packing styles for procurement, manual dismantling, roasting, crushing and segregation, and in the structures of handling facilities and baskets to streamline commercial operations and reduce their energy consumption. The development of a high-volume treatment system will start in FY 2019 and commercial operations are scheduled to commence in FY 2021, with the input and The development of a high-volume treatment system will start in FY 2019 and commercial operations are scheduled to commence in FY 2021, with the input and output processes streamlined and the licence obtained for demonstration facilities, etc. xvi xvii  Implementing entities Taiheiyo Cement Corporation Project implementation system Deputy General Manager, Environmental Business Unit Leader, Sales Planning Group Director in charge of the Environmental Business Unit Sales Planning Group Environmental Division Counsellor, Sales Planning Group Environmental Division Assistant Manager, Sales Planning Group Environmental Division Sales Planning Group Principal Officer Environmental Division Sales Planning Group Principal Officer Central Research Institute, Research Department 3 Separation Technology Team Leader Central Research Institute, Research Department 3 Senior Researcher, Separation Technology Team Central Research Institute, Research Department 3 Senior Researcher, Separation Technology Team Central Research Institute, Research Department 3 Researcher, Separation Technology Team Central Research Institute, Research Department 3 Researcher, Separation Technology Team Central Research Institute, Research Department 3 Researcher, Separation Technology Team field of early-blooming (or ripening) rice consideration Hanada Takashi Fukuda Seiji Kenichi Mori Suzuki cool Uesugi court (national) mourning Ishida Yasuyuki City Village China Central Hon. Kenichi Takemoto. Tomonori Nakamura Mitsushi Komatsu Kohei  Re-consignee. Matsuda Sangyo Co. Cleco Labs Ltd. Central Research Institute, Research Department 3 Researcher, Separation Technology Team Takizawa valiant Environmental Solutions Division Deputy General Manager, Solutions Sales Department Environmental Solutions Division Planning and Promotion Division section manager Production Headquarters Technical Development Section Assistant Section Chief Production Headquarters Technical Development Section technical assistant representative director (i.e. someone chosen by the board of directors from among the directors to represent the company) manager (e.g. of a business, an idol, etc.) boundary Kenichiro Yano man of valor Urata Yasuhiro Akihiro Okochi Kozu Seiroku Wakabayashi Shiko 1. Implementation of demonstration projects 1.1 Overview of the demonstration project 1.1.1 Objectives, background, issues, etc. The project aims to demonstrate a low-carbon recycling system for used lithium-ion batteries ('LIBs').Thetechnological development of recycling treatment that has been promoted so far has mainly targeted small LIBs and has lagged behind in dealing with large LIB packs/modules. However, with the spread of next-generation vehicles, there is now a need to develop recycling technologies for large LIB packs and modules. Heat treatment is essential for LIB modules because of the risk of ignition and plant accidents if they are crushed directly. However, heat treatment requires a large amount of energy, and the recovery of rare metals such as lithium, cobalt and nickel contained in LIB modules is problematic. At present, electric furnaces and stationary furnaces are available as treatment methods for LIB modules, but in electric furnaces, only iron is recycled and other base metals and rare metals are not recovered, while in stationary furnaces, base metals and rare metals are recovered, but they are in an oxidised state at high temperatures, so there are issues with their integrity. In order to recycle used large LIB packs and modules in a low-carbon treatment scheme, this demonstration project aims to demonstrate the recovery of high-quality metal resources from large LIB packs and modules using a roasting furnace. The treatment targets are a wide variety of large LIB packs and modules for automotive, stationary and other applications. The ultimate goal is to recover and recycle lithium, which has not been recovered so far. The objectives, background and issues are shown in the diagram below. 1 Objective. target waste Recycling of lithium ion batteries (LIBs) in low-carbon processing schemes. The ultimate goal is to recover and recycle previously unrecovered lithium compounds <Low carbon Design of systems that utilise waste heat from the cement calcination process to reduce energy c<oRnessuomuprtcieon in the roasting process. recycling>. Selection of treatment processes to recover metal resources (rare metals and base metals such as lithium compounds) respectively. <Other environmental impact remediation>. Design of a low-cost detoxification system for the treatment of hydrogen fluoride gas generated in the heat treatment of LIB in a cement calcination furnace. Automotive and stationary LIBs backgroun d H29 Outco me. The spread of next-generation vehicles requires the development of recycling technologies for a wide variety of large LIBs. Increased demand for lithium due to the widespread use of LIBs has created demand for lithium recycling. Direct crushing of LIBs without heating can lead to ignition and plant accidents. Heat treatment is essential, but requires a lot of energy consumption. Metal recycling, as detoxification in electric furnaces can only recover iron, while in stationary furnaces the metal is oxidised. (base metals and rare metals) have challenges. High environmental impact of exhaust gases, such as the generation of difficult-to-treat hydrogen fluoride gas when heated. Three types of LIBs were used in the roasting experiments: one for vehicle-mounted use (domestic and international) and one for stationary use. FY30. enforceme nt agenda The two temperature zones of 450C and 600C were compared and verified, with the result that 450C was preferable. The heating time was compared between 3 hours and 6 hours at 450 C. The results showed that 6 hours was preferable. The structure of LIBs varies widely, and the effective roasting conditions etc. depend on the material of the frame (iron, resin). CO2 emissions in the heat treatment process are expected to be reduced by approximately 70% (comparison: stationary furnace). (i) Roasting a wide variety of LIBs and testing effective methods. Roast a wide variety of LIBs in terms of type, total weight, remaining total power, etc., and compare and verify roasting conditions that can be applied to a wider range of LIBs. (2) Verification of roasting conditions (temperature and time) for high effective recovery of lithium compounds. In order to study roasting conditions that enable higher effective recovery of lithium compounds, tCeomndpuecrtaintgure zones, time zones, etc., were set in detail, and the specific comparative (vieirii)fiVcaetrioinfi.cation of operational requirements, etc. for continuous operation for practical use. Investigate operational methods to quadruple the daily throughput compared to last year's results and to ensure continuous operation in high-volume processing. Verify operational requirements for commercialisation (e.g. mass processing, stable operation), identify and organise improvement issues Figure 1-1. Objectives, background and issues of this demonstration project 2 1.1.2 implementation system A diagram of the project's implementation structure is shown in Figure 1-2. In implementing the project, Pacific Cement, Creco Regular meetings were held at the beginning of each month at Labo, Matsuda Sangyo and other three companies to confirm monthly progress and to check, share and discuss issues such as implementation items and targets for the following month. Taiheiyo Cement oCvoerrpaollrsautipoenrvision Demonstration test plan developed Business plan developed Project scheme development Assessment and studyof business viability and profitability adviser joint venture outso urcing University Research Institutes (Shimane University/Associate Professor Sasai) Cleco Labs Ltd. Matsuda Sangyo Co. Lithium extraction from recovered cathode and anode materials and Assessment, etc. related to recovery as lithium carbonate, etc. Support for the development of demonstration test plans Support for trial calculations of CO2 emissions/energy-saving effects, etc. Support for compilation of results of demonstration test surveys Support for business profitability verification Support for compilation and preparation of reports Tsuruga Cement Co. Hiroshima Gas Techno Service Co. Pacific Consultants Ltd. etc. Figure 1-2. Implementation structure diagram Dismantling of LIB packs Crushing and sorting of LIB roasting materials and recovery of metals Roasting operations for LIB modules LIB module roasting operations using batch furnaces. Chemical analysis of recovered materials (mainly positive and negative electrode materials etc.)/. Physical properties and fuel testing Measurement of exhaust gases from roasting demonstration plant systems. 3 1.1.3 System of demonstration projects In this demonstration project, the roasting temperature is adjusted to prevent melting and oxidation of the metal, while only combustible content and adhesives are roasted to facilitate recovery of metal resources. By crushing and sorting the roasted LIB modules, not only the base metals are recovered, but also rare metals such as lithium are concentrated to a concentration that enables recovery of the materials, thereby facilitating metal recycling. Furthermore, as an energy-saving measure, the roasting furnace is located next to the cement calcination furnace and the exhaust heat from the cement calcination process is used in the roasting furnace, thereby reducing the amount of energy consumed for roasting. In addition, the exhaust gas containing flammable gases generated by roasting is returned to the cement calcination process and used as a fuel substitute, and the difficult-to-treat hydrogen fluoride contained in the exhaust gas is treated by the cement calcination furnace at low cost. The aim is to build a treatment system that enables the recycling of all LIB packs and modules at a lower cost than other technologies. The concept of the roasting process is characterised by the fact that the spent LIB modules are placed in a metal container (basket) and fed into the roasting furnace, which has a double structure. This creates low-oxygen conditions and prevents a rapid temperature rise due to the combustion of the LIB and the melting and oxidation of the metal, while also allowing the roasting conditions to be set according to the input material. Furthermore, the plant is located adjacent to a cement calcination furnace, and hydrogen fluoride gas generated by the roasting of spent LIB modules is returned to the cement calcination furnace, enabling low-cost fluorine detoxification treatment and energy saving in the cement calcination process through the effective use of heat from the roasting exhaust gases. The concept of the crushing and sorting process is the recovery of electrode powder with a high concentration of rare metals such as lithium, and is characterised by the pursuit of economic efficiency by increasing the metal recovery rate and the realisation of 100% recycling by turning the residues into cement resources. Used lithium-ion battery recycling and treatment system. cement plant no longer used lithium ion battery waste heat Demonstration project scope Collectio sorti n, ng transport and and sorti transship ng recovery of ment and valuables storagebase metal Plastics (iron, aluminium, copper) torref actio n flammable exhaust gas (containing hydrogen fluoride) Cement raw fuel recycling crus hing selec polar powder (Contains rare metals) tion recovery of valuables base metal (iron, aluminium, copper) Rare metal rem recover ainin y g recovery of valuables rare metal (e.g. lithium compounds) 4 Collection/transport of waste battery packs Battery pack dismantling Roasting furnaces Roasting materials Resource sorting Figure 1-3. System of the project Shredding and sorting 5 1.1.4 Implementation flow of the demonstration project The implementation items, studies, objectives and results of each step of this demonstration are shown in the diagram below. Overview of the demonstratio n project (i) spent LIB pack Separation and manual demolition base metal plastic (ii ) cement firing wast e heat torref actio n containing hydrogen fluoride flammable exhaust gas burnt offering (i.e. religiou s animal sacrific e) (ii i) Crushing and sorting experime ntal study polar powder Lithium compounds, etc. Rare metal content base metal desk checking Composition and other analysis enforcement Details Objectives agenda of /outcomes implem . entation (i) of used LIB packs. Separation and manual demolition Hand dismantling of a wide variety of used LIB packs Weighing of recovered resources Measurement of voltage, current, etc. Capturing disposal status data in a wide variety of LIB packs Obtaining data on the amount of resources collected in a wide variety of LIB packs (ii) Roasting of spent LIB modules Detailed verification of roasting conditions for dismantled LIB modules H29: 450C, 600C/3hr-6hr H30: 400-550C/4hr- 8hr Investigation of the effect of dismantled LIB modules on the roasting process. More detailed roasting conditions for higher effective recovery of lithium compounds. study A wide variety of LIB module types, unit throughput, H29: Small quantity (2 baskets/day), 3 species remaining power, etc. H30: High volume (8 baskets~/day), multiple species, total Comparison of roasting of LIB modules weight, total remaining power, etc. Measurement of the recovery accuracy of rare metals (e.g. Li) in Measuring the behaviour of rare metals (e.g. Li) and fluorine. the roasting process (checking the overall behaviour H29: Roasting ware including roasting and flue gas). H30: Roasting and exhaust gases. Estimated energy savings from the effective use of exhaust Energy savings from the effective use of waste heat from the cement calcination heat from the cement calcination process and exhaust gas from process and exhaust gases from roasting furnaces. roasting furnaces, using cement calcination furnaces at different levels of roasting conditions, etc. trial calculation (iii) Roasted LIB Modjes Recovery of resources from the Pre-processing for resource recovery (crushing and sorting (shearing type (with particle size adjustment function)) Analysis of resource recovered materials by level of roasting conditions, etc. (Measurement of Li, Co, Ni, Cu, Fe, Al) Shredding and sorting processes for resource recovery Comparative verification of resource recovery effectiveness. Overall design of LIB pack treatment and recycling flow. Overall design of treatment and recycling schemes Can be used with a wide variety of LIB modules, and has better MCaotnersiaidl ebaralatniocne corferaotiaonsting conditions resource recovery efficiency. Investigation of roasting conditions, etc. Treatment schemes. Waste heat from the cement calcination process and roasting furnace exhaust Material balance in treatment and recycling flows. Overall design and gas, utilising the adjacent cement calcination furnace. Design and operation methods for low-carbon systems that economics Study of design and operation methods for a low-carbon system that makes make effective use of waste heat from the cement calcination Re-examination of the effective use of process by placing the cement calcination furnace and roasting furnace next Verification of economic efficiency in the design flow. to each other, detoxify fluorine-hydrogen gas in the exhaust gas Business scheme business competitiveness estimates from collection to from the roasting furnace, and use flammable exhaust gases as treatment in a hypothetical model. alternative fuel. Planning of economically feasible treatment schemes. Organisation of future issues and development of business plans Figure 1-4. Overview of the implementation of this demonstration project 6 (1) Experiments on separation and manual dismantling of used LIBs As a pre-treatment for the roasting process, the LIB packs were dismantled by hand as required. The LIB packs used are for on-board use. Dismantling of stationary LIB packs was not carried out as it was not necessary. Weights etc. were measured before and after dismantling and a material balance was prepared. Pre-dismantling LIB packs (vehicle-mounted) Dismantling operations LIB module insulation work Recovered resources Figure 1-5. Disassembly and manual disassembly of used LIB packs in this demonstration project (2) Experimental roasting of spent LIBs The dismantled LIB modules are fed into a roasting furnace (test furnace) and the heating temperature range and time are selected to suit metal recovery. The roasted material produced (e.g. pole powder) is used for crushing and sorting in the next process. In addition, the fuel substitution effect of the effective utilisation of the flue gas containing combustible gases generated from the roasting furnace in the cement calcination process is estimated. The roasting furnace used in this experiment is a project subsidised by the Ministry of Economy, Trade and Industry (*) and installed at Tsuruga Cement Co. 1) a rotary bed continuous roasting furnace (test f u r n a c e ) introduced for the purpose of lithium-ion battery recycling and 2) a small fixed incinerator (test furnace) of Hiroshima Gas Techno Service Co. The roasting furnace of Tsuruga Cement was mainly used, and the furnaces of both Tsuruga Cement and Hiroshima Gas Techno Service were used to confirm the impact of residual power. 1 Subsidy for the development of practical industrial technology in 2014 (Resource Recycling Demonstration Project). 2014 Subsidy for the development of practical industrial technology (Demonstration project for the recovery Top view of the roasting furnace basket 6 No. 3 Burner basket 7 No. 4 Burnbearsket 8 basket basket pusher 5 1 double shutter basket basket 7 4 2 basket 3 input port No. 1 Burner No. 2 Burner input port of rare metals with recycling priority). Figure 1-6. Roasting furnace in this demonstration project (Tsuruga Cement) (Remark: the size of the furnace interior is 3,400 mm, height 1,500 mm) 8 Figure 1-7. Roasting furnace in this demonstration project (Hiroshima Gas Techno Service) (Remark: the size of the furnace interior is 560 mm (W) x 1000 mm (D) x 900 mm (H)) (3) Experiments in crushing and sorting roasting materials Shear crushing and sieve sorting are used as methods to recover lithium and other materials from roasted materials (e.g. electrolyte powder) generated in a roasting furnace with high efficiency. In the scope of this demonstration, the recovery and component analysis of the electrode powder containing lithium, etc. will be carried out. Figure 1-8. Crushing and sorting equipment in this demonstration project 9 1.2 Results of the demonstration project 1.2.1 Experiments on separation and manual dismantling of used LIBs In this demonstration project, a wide variety of LIB packs were dismantled by hand as a pre-treatment for the roasting process. This year, 10 types of LIB packs (modules for stationary use) were dismantled, compared to three types last year. Only vehicle-mounted (domestic and foreign) LIBs discharged in packs were dismantled by hand. As a result of manual dismantling, an average of approximately 40% (by weight) of metal and plastic material was recovered per vehicle LIB pack, both nationally and internationally. Table 1-1. Breakdown of samples used (unit: pcs) cathod e materi al NCM NCM+. NCM (Mn LMO LTO LFP corner Rich). (e.g. cell shape laminat e cylinde r desk, For in- vehicle use For in- vehicle fuosr e stationa ry use for stationa ry use outsi de the coun oturytsi ddoem etshteic coouutsni dtrey dthoem ceosutinc oturytsi ddoem etshteic coun try dom estic 16 aluminiu m 26 71 0 204 0 0 Cell housing material 10 0 stainless steel 0 322 24 0 iron 0 100 Unit pwaevigehmte(nweight/number of modules) t) 0 Less than 10 kg 0 17 1026kg or 0 more Less than 20 kg 16 502 24 0 20 kg or more 10 8 0 0 0 0 0 0 0 322 8 162 364 8 0 0 0 0 0 0 0 79 0 79 0 0 79 0 0 64 15 0 (Remark: for vehicle-mounted applications, the LIB is in LIB packs; for stationary applications, the LIB is in LIB modules). 10 Table 1-2. basic information LIB Type manuf Type. acture Material balance and residual voltage etc. in LIB packs cathode Modular structure cell Cell Module size pack (Numbe r of material shape housing (mm) pieces) r material PHEV NCM corner aluminium 400*180*110 6 outsid (e.g. e the desk, pavemen countr t) For iny EV NCM (Mn corner aluminium 410*300*150 3 vehicle rich). (e.g. desk, use pavemen t) basic informPaHtioEnV NCMResidualcPoronweerr aluminium 320*135*110 4 Measurem(ee.ngt. LIB Type manuf Type. daoctmuree Voltag e (V) deCsukr, rent pavemen t)(mA)1) sr tic PHEV LFP corner aluminium 380*180*140 9 PHEV 58.5 (e.g8.1.3 outsid EV 46.7 padveesm6k4,e.n8 e the t) countr EV LMO lamina aluminium 320*220*65 1 For in- te y EV NCM (Mn corner stainless 440*190*120 25 vehicle PHEV r5ic6h.)5. (e.g7.8.4 steel use PHEV 34.8 des4k8, .3 EV 7.3 pavem10e.n1 dome HEVV 32.5 t)45.1 NCM corner aluminium 570*160*130 15 HV stic 98.1 (e.1g3. 6.2 HV 166.5 des2k3,1.3 (HV) 0 paveme0n - 0 t) 0 for dome H-V NC0M cylinde0 iron 625*310*110 10 stationar stic r (HV) NCM+LTO corner aluminium 200*180*80 - y use (e.g. 1) Connect an electrical resistance of 720 and dcaersryk,out current measurements. pavemen basic informati-on for dome stationar LyIBusTeype stic manuf acture r Type. - outsid PHEV e the t) NCM + LTO coprnaeckr ed aanludminium (ed.gis.mantled deysekrb, a mat pavembeanllat modul iron t) non- plastic NCeM + LTO cornefer rroualuminium (e.g. s 72.3% 4.8%desk,22.3% pavemen 0.2%. t) 178*207*154 use - total am1o8u7n*358*120 - t 99.7%. October Roasting trials (discharged, undischarged) countr EV 81.4% 2.8%. 15.8%. - 100.0%. October Roasting trials For in- y 11 vehicle use PHEV PHEV dome EV stic EV 44.7% 74.6% 65.9%. 73.5%. 35.4% 4.8% 31.1% 2.6% HV 67.6% HV 41.9%. (HV) 100.0%. - for dome stationar stic - y use 53.1% 53.1% 24.3% 48.4% 36.6% 36.6% 12.1% 19.0% 2.9%. 19.1% 8.1% 8.0% 0.0% 10.1% 10.1% 7.8% 1.7% 0.1% 4.8% 1.3% 0.2%. 0.2%. 100.0%. 100.0%. 100.0%. 100.0%. 100.0%. 99.6%. 100.0%. 100.0%. 100.0%. October Roasting trials October Roasting trials October Roasting trials July-October Roasting trials (discharged, undischarged) October Roasting trials October Roasting trials October Roasting trials October Roasting trials October Roasting trials 12 1.2.2 Experimental roasting of spent LIBs Roasting treatment experiments were conducted on the dismantled LIB modules by dividing them into type, unit throughput, remaining total power, etc., to verify the effect of different LIB modules on the roasting treatment. The verification items of the project are listed below. Table 1-3. Verification items in the roasting process of LIB modules impleme evaluation summary chapter ntation technique level (1) Roasting Union of roasting Component analysis condition temperatures and roasting Checking paraffin s times consumption. Exploring Level-specific roasting Exhaust gas the experiments by component analysis (1) Search for roasting conditions (4-8 baskets per level) Measurement of temperatures in the <Level of implementation>. furnace, exhaust gases, 400C 4 hours. x- 6 8 hours. hours. symb symb etc. during roasting. mark ol ol (used used used to as a as a indicat place place e an holde holde incorr r r ect (eithe (eithe answe r r r in a beca becau test, use a se a etc.) numb numb er of er of other other word words s could could be be used used in that in positi that on or positi becau on or se of beca censo use rship) of cens orshi p) 450C x- symb symb mark ol ol (used used used to as a as a indicat place place e an holde holde incorr r r ect (eithe (eithe answe r r r in a beca becau test, use a se a etc.) numb numb er of er of other other word words s could could be be used used in that in positi that on or 13 positi becau on or se of beca censo use rship) of cens orshi p) 500C symbo symb x- . l used ol mark (1) Exploration of roasting conditions For the recovery of high concentrations of base and rare metals, more precise comparative verification was carried out on the roasting temperature range and heating times that do not melt the aluminium and copper of the electrode materials, burn off only the adhesive and have good recovery rates of the rare metals. Last year, a combination of 450C-6hr was considered suitable, but a more detailed comparison with a more detailed verification temperature range resulted in the highest recovery of rare metals below 1 mm and base metals above 1 mm at 500C-4hr. The distribution ratio of lithium between the recovered material after crushing and sorting and the flue gas also showed that the highest amount of lithium was recovered at 500C-4hr to lessthan1 mm. The amount of paraffin used per treatment volume was also lowest at 500C-4hr. From these results, 500C-4hr was judged to be the optimum roasting condition. 100%. Li distributio n ratio <1 1 100%. Co distributi on ratio <1 1 100%. Ni distributi on ratio <1 1 sharing ratio sharing ratio sharing ratio 50%. 50%. 50%. 0% 0% 0% sharing ratio 100%. 50%. 0% Figure 1-9. Cu distributi on ratio <1 1 100%. Al distributio n ratio <1 1 100%. 50%. Fe distributi on ratio <1 1 sharing ratio sharing ratio 50%. 0% 0% Distribution of recovered resources by roasting temperature and roasting time Table 1-4 Amount of lithium per tonne of LIB module by level Less than 1 More than 1 mm (%) mm (%) 400C- 85 15 6hr. 400C- 88 12 8hr. 450C- 88 12 6hr. 450C- 89 11 8hr. 500C- 91 9 4hr. 500C- 85 15 6hr. 550C4hr. 86 14 14 550C- 85 15 6hr. level (distribution ratio) Exhaust gas (%) 0 0 0 0 0 0 0 0 Table 1-5. Kerosene consumption by level Roasting Paraffin Temperature conditions consumptio measurement level n Set temper ature (C) Hours . (hr) Kerosene consumption per unit time (L/hr) Per unit module volume Paraffin consumption (L/kg-LIB) Furnace temperat ure (C) Exhau st gas temp eratu re (C) 400C-6hr. 400 6 23 0.55 409 401 400C-8hr. 400 8 23 0.74 410 394 450C-6hr. 450 6 27 0.65 459 438 450C-8hr. 450 8 27 0.86 461 442 500C-4hr. 500 4 31 0.50 508 494 Per unit module volume Paraffin (L/kg-LIB) consumptio n Hours (hr) 500C-6hr. 500 6 31 0.864 0.74 505 481 550C-4hr. 550 4 0.736 34 0.54 0.816 552 533 550C-6hr. 5501 6 304.648 0.744 0.82 553 538 0.552 0.496 0.544 0.5 0 400 450 500 550 Temperat ure (C) 8 6 4 Figure 1-10. Kerosene consumption per unit module volume by level 15 (2) Confirmation of impact on fuel use per input. A comparison of kerosene consumption by input volume confirms that increasing the input volume reduces kerosene consumption. level (Input). (kg) 100 250 Table 1-6. Kerosene consumption per input Paraffin Temperature Roasting conditions consumptio n Kerosene Kerosene consumption per consumption per unit time (L/hr) unit module volume (L/kg-LIB) measurement Furnace temperat ure (C) Exhaust gas temperatur e (C) 500C-4hr. 34 0.54 503 485 500C-4hr. 31 0.50 508 494 16 (3) Check residual power impact. In order to confirm the effect of residual power in the LIB module on roasting, roasting tests were conducted with and without discharge, and the temperature inside the basket and the amount of paraffin used during roasting differed depending on whether the LIB module was discharged or not, confirming that differences in residual power (with or without discharge) had an effect on the roasting process. This confirmed that the difference in residual power (with and without discharge) had an effect on the roasting process. In addition, a comparison of paraffin consumption showed that paraffin consumption was lower without discharge. This is presumably due to the contribution of residual electricity as fuel. Table 1-7 Photographs of LIB module roasting experiments with and without discharge pre-roasting (left: discharged, right: (Note: Filmed at HiruonsdhismcahaGragseTde) chno Service). after roasting (Top: discharged, bottom: undischarged) 600 500 400 Basket internal temperature (C) Foreign automobile 300 manufacturers with discharge 200 Foreign automobile 100 0 0 manufacturers without discharge Domestic 0.5 1 1.5 a2utomobil2e.5manufac3turers with3.5 4 Roastingditsicmhearg(her) Domestic Figure 1-11. Temperature inside the baautsomkeobtilwe ith maanndufawcittuhreorsut discharge (Remarks) The roasting temperature is 500C. without discharge 17 Table 1-8. input level (kg) Kerosene consumption by presence of discharge during Roasting conditions Kerosene normal operation Kerosene consumption per consumption per unit module volume unit time (L/hr) (L/kg-LIB) No 250 500C- 31 0.50 discharge 4hr. (Reference)WSituhbmer2g5e0d test re5s0u0ltsCo- f LIB module3s5. 0.56 In orddisecrhtaorgdeischarge the LIB 4mhor.dules, domestic and foreign automobile manufacturers LIB modules were submerged in water. When the submerged treatment was carried out, bubbles were generated immediately after submergence, and white or yellow turbidity covered the water surface. Wastewater Component analysis showed that effluent standards were exceeded for six items (BOD, COD, F, Cu, Zn and Cr). This indicates that submerged treatment of LIB modules must be carried out in a facility equipped with wastewater treatment facilities . Table 1-9. Photographs of spent LIB modules submerged in water Domestic automakers foreign automobile manufacturer 18 (4) Confirmation of the influence of LIB module type and continuous roasting furnace operation with a wide variety of LIB modules. In order to confirm the influence on the roasting process by the LIB module type, and to confirm the roasting results in the continuous roasting furnace operation using many kinds of LIB modules, a demonstration experiment was conducted using various kinds of LIB modules. As a result, a large amount of base metals could be recovered at 1 mm or more as targeted regardless of the type of LIB module but the recovery of rare metals remained at around 50 % as in the previous year. operational know-how was gained, such as not mixing and bad . When paraffin consumption was compared between roasting a single type and roasting a mixture of many different types, paraffin consumption per unit was lower when roasting in the mixed state. Other lithium behaviour was confirmed in a continuous roasting furnace operation using many types of LIB modules, and it was confirmed that the lithium did not fly into the exhaust gas. 100%. Li distributi on ratio <1 1 100%. Co distributi on ratio <1 1 100%. Ni distributi on ratio <1 1 sharing ratio sharing ratio sharing ratio 50%. 50%. 50%. 0% For on-board For on-board For on-board For on-board For onboard For on-board Stationary mixing (International)1 (Domestic)2 (Domestic)3 ( D o m e s t i c ) 4 ( Domestic)5 (Multispecies) 100%. Cu distributi on ratio <1 1 0% For on-board For on-board For on-board For on-board For onboard For on-board Stationary mixing (International)1 (Domestic)2 (Domestic)3 ( D o m e s t i c ) 4 ( Domestic)5 (Multispecies) 100%. Al distributi on ratio <1 1 0% For on-board For on-board For on-board For on-board For onboard For on-board Stationary mixing (International)1 (Domestic)2 (Domestic)3 ( D o m e s t i c ) 4 ( Domestic)5 (Multispecies) 100%. Fe distributi on ratio <1 1 sharing ratio sharing ratio sharing ratio 50%. 50%. 50%. Figure 1-12. Percentage distribution of recovered resources 0% 0% 0% For on-board For on-board For on-board For on-board For on- For on-board For on-board For on-board For on-board For on- board For on-board Stationary mixing board For on-board Stationary mixing (International)1 (Domestic)2 (Domestic)3 ( D o m e s t i c ) 4 (International)1 (Domestic)2 (Domestic)3 ( D o m e s t i c ) 4 (Rema( rDokmessti:c)5R(Muoltispaecises)ting conditions: 500C-4hr()Domestic)5 (Multispecies) by LIB module type For on-board For on-board For on-board For on-board board For on-board Stationary mixing For on- (International)1 (Domestic)2 (Domestic)3 ( D o m e s t i c ) 4 ( Domestic)5 (Multispecies) Table 1-10. Kerosene consumption by LIB module type and in continuous operation Cell level Manufact cathode cell housi urer used material shape ng mater ial Module size (mm) Operating conditions (batch or continuous, roasting time) For invehicle use 1 outside the country NCM (Mn rich). corner alumini (e.g. um desk, pavemen 19 t) 410*300*150 Batch, 4hr. For invehicle domestic NCM (Mn rich). corner (e.g. stainle ss 440*190*120 Batch, 4hr. Kerosene unit module quantity Furnace level Manufact consumption per Paraffin temperat urer used unit time (L/hr) consumption per ure (L/kg-LIB) (C) For in- outside 26 vehicle the use 1 country For in- domestic 31 vehicle use 2 Automotiv domestic 32 e 3 Automotiv domestic 25 e 4 fixed domestic 28 mixture mixture 11 (wide variety) 0.41 511 0.50 505 0.63 507 0.38 521 0.45 518 0.09 541 Exhaust gas temperatur e (C) 489 494 486 500 496 503 Table 1-11. level For in-vehicle use 1 For in-vehicle use 2 Automotive 3 Automotive 4 fixed Mixed (wide variety) Lithium distribution rates by LIB module type and in continuous operation Manuf Amount of lithium per tonne of LIB module (distribution acturer ratio) used Less than 1 mm (%) More than 1 mm (%) Exhaust gas (%) outsi 84 16 0 de the coun try dom 91 9 0 estic dom 71 29 0 estic dom 28 72 0 estic dom 39 61 0 estic 20 mixt 56 43 0 ure 1.2.3 Experiments in resource recovery from roasting and burning materials. For highly efficient recovery of base metal and polar powder (<1 mm) containing lithium and other materials from roasted materials. As suitable crushing and sorting methods, shear crushing and sieve sorting, which were selected in last year's demonstration project, wereused.LIB modules by type recovered metal material balance is shown below. Last year, the average lithium recovery rate was about 50%, but this year, depending on the input level, more than 80% lithium was successfully recovered in less than 1 mm. Highly efficient rare metal recovery is considered to be possible by devising the LIB module configuration to be fed. LIB module torrefact ion Li. For invehicle 100 use (Domest ic)1 For invehicle 100 use (Domest ic)2 For invehicle 100 use (Outside the country) 3 For invehicle 100 use (Domest ic)4 fixed (Domest 100 ic) consec utive 100 (Mixed) Figure 1-13. exhaust fumes burnt Co offNeir.i Cu 100 n1g00 100 (i.e. religio 100 u1s00 100 anima l 100 sac1r0i0fi 100 ce) Crushing and sorting Al. Fe 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 <1 mm (Active substance ) 1 mm Li. Co Ni. Cu Al. Fe For in- vehicle 84 85 83 3 8 1 use (Domest ic)1 For invehicle 91 91 90 3 13 1 use (Domest ic)2 For in- vehicle 71 52 38 4 9 1 use (Outside the country) 3 For in- vehicle 28 30 24 4 3 0 use (Domest ic)4 fixed (Domest 39 16 16 17 3 7 ic) consec utive 57 46 47 11 6 7 (Mixed) Last year: Automotive (domestic) Li, Co, Ni = 53,53,54 Automotive (outside Japan) Li, Co, Ni = 53, 78, 50 Li. Co Ni. Cu Al. Fe For invehicle 16 15 17 97 92 99 use (Domest ic)1 For invehicle 9 9 10 97 87 99 use (Domest ic)2 For invehicle 29 48 62 96 91 99 use (Outside the country) 3 For invehicle 72 70 76 96 97 100 use (Domest ic)4 fixed (Domest 61 84 84 83 97 93 ic) consec utive 43 54 53 89 94 93 (Mixed) Material balance of recovered metals by LIB module type 21 Table 1-12. terms and conditi ons Photographs of roasting and recovered material after crushing and sorting by roa<1sting temperature and roasting time 1 mm m m 400C 6hr. 400C 8hr. 450C 6hr. 450C 8hr. 22 terms <1 and mm conditi ons 500C. 4hr. 500C. 6hr. 550C 4hr. 1 m m 23 550C 6hr. .. ... z 7\k m , -. / 00.:f 0 C 9 0:.) . ...10: r W.t '. . 24 Table 1-13. Type. Photographs of roasted LIB modules by type and recovered material after crushing <1 and sorting 1 mm m m For invehicle use 1 For invehicle use 2 For invehicle use 3 For invehicle use 4 25 Type. <1 mm for station ary use mixtur e (Wide variety . Diverse ) (Remarks: Roasting conditions: 500C-4hr) 1 m m 26 1.3 Overall design of treatment and recycling schemes Based on the results of the demonstration experiment, the overall design of the spent LIB pack recycling flow was carried out and the recycling flow material balance was calculated. As a treatment flow for used LIB packs , the LIBs in the pack state are dismantled by hand, the base metal and plastic are recovered, the LIBs are made into modules, and then roasted. The roasted materials are crushed by shearing, sieved, and the sorted and collected materials (less than 1 mm) are sorted and collected. Polar powder is recycled as lithium and other rare metal recycling, while more than 1 mm is recycled as copper recycling. The scale of the processing scheme is based on the experimental data from this year, with a roasting processing volume of 3,000t/year (10t/day) as the axis. The total amount of used LIB packs to be processed is estimated to be about 4,600 t/year, while the resources to be recovered are 744 t/year of polar powder and a total of about 3,140 t/year of base metals. Figure 1-14. Overall design of treatment and recycling schemes (Remark: LIB pack Material balance is a value for a mixture (of many varieties). Roasting furnace to cement calcination furnace Combustible gas Properties 200C/165 kcal/kg and cement calcination furnace to roasting furnace Thermal energy 150C are based on the results of last year's study). To pre-heater. Cooler and flue connections potential gas induction fan clinker cooler Cement firing process Exhaust heat from (to be established in the future). incinerator 27 incinerator flue gas flue LIB storage facilities Figure 1-15. Design and operational approach for a low-carbon system using an adjacent cement calcination furnace. 28 2. Verification of environmental impact reduction benefits. 2.1 Examination of the effects of resource recycling The recycling effect of the actual resource recovery from the content concentration is shown below. The resource recovery rate was approximately 30% for the Automotive 2, approximately 48% for the Automotive 4 and approximately 38% for the Mixed. This difference is not due to the recovery rate of rare metal , but to the material composition ratio of LIB packs . In the previous year, the rate was approximately 61% for vehicle-mounted (average) use. The reason for the decrease in the resource recovery rate is thought to be due to the different amounts of ferrous and non-ferrous that make up the LIB packs. Therefore, the resource recovery rate of LIB packs is considered to depend on the content of the materials that make up the LIB packs. In the case of rare metal recovery pole powder that is not expected to be recycled, it should be recycled as cement, or it should be recycled as a waste material. The recycling rate is 100%, as in the previous year, because the amount of landfill for any LIB packs in the project is zero. Table 2-1. Unit: t/t For invehicle use LIB Automotive 2 (domestic) - EVs Automotive 4 (domestic) - HV Mixed (wide variety) Unit: t/year For invehicle use LIB Automotive 2 (domestic) - EVs Automotive 4 (domestic) - HV Mixed (wide variety) Results of the evaluation of resource recycling effects in the project throughput iron non-ferrous plastic Li. Co Ni. Cu (resource) recycling rate (Aluminium) recovery rate 1.00 0.03 0.19 0.05 0.00E+00 0.00E+00 0.00E+00 0.07 33.2%. 100.0%. 1.00 0.24 0.08 0.00 9.77E-04 3.09E-03 6.67E-04 0.15 48.0%. 100.0%. LIB 1.00 pack throughp ut 4,083 iron 0.22 non-ferro0u.1s1 (Aluminium) plastic0.02 0.00E+00 Li. 0.00E+00 Co 0.00E+00 Ni. 107 781 195 0 0 0 0.03 Cu 272 37.9%. Volume of resources recovered 1,355 100.0%. 4,435 1,077 359 0 4 14 3 672 2,129 4,573 1,019 481 81 0 0 0 151 1,732 (Note: Non-ferrous metals are assumed to be aluminium rated). Table 2-2. Unit: t/t Automotive LIBs Stationary LIB dome stic outsi de the count ry avera ge Results of evaluation of resource recycling effects in H29 projects (indicative) throughpu t 1.00 iron 0.32 non-ferrous (Aluminium ) 0.21 plus chick 0.05 Li. 7.68E-04 Co 1.94E-03 Cu 0.11 (resource) recovery rate 68.8%. recycling rate 100.0%. 1.00 0.02 0.35 0.04 0.00E+00 0.00E+00 0.11 52.5%. 100.0%. 1.00 1.00 0.17 - 0.28 - 0.05 - 7.19E-04. 2.39E-03 3.37E-03 4.90E-03 0.11 6.80E-04 61.0% 1.3% 100.0%. 100.0%. Unit: t/year non-ferrous plus throughpu iron (Aluminium chick Li. Co Cu Volume of 29 Automotive LIBs Stationary LIB dome stic outsi de the count ry avera ge t 7,000 5,111 5,908 3,000 2,222 111 1,002 - ) 1,444 1,778 1,637 - 333 222 269 - resources recovered 5 14 799 4,818 0 0 574 2,685 4 20 669 7 15 2 3,602 40 30 2.2 Study of the effects of reducing CO In calculating the carbon dioxide reduction effect of the project scheme, the incineration process in a stationary furnace was set as the technology to be compared. Since it was difficult to obtain data on energy consumption in the treatment process before and after incineration in a stationary furnace, the hydrogen fluoride treatment process was excluded from the scope of calculation, assuming it to be the same as in the Project as a more conservative calculation. The recycling effect was included in the calculation only for the amount of resources that is actually assessed. As a result of the trial calculation, the CO2 emission reduction effect per tonne of LIB packs was calculated to be 171 kg-CO2/t in the case of 2 for vehicle use, 242 kg-CO2/t in the case of 2 for vehicle use and 434 kg-CO2/t in the case of mixed (various types of) packs. Last year, the average value for vehicle-mounted LIB packs (average) was approximately 300 kg-CO2/t, and therefore, for mixed (diverse) emissions reduction results due to a reduction in kerosene use compared to Baseline process Spent LIB packs boundary B iro n *Assumed to be identical to the Project. Separation antwd omanuapl lus demmoi lition chick energy A Incineration (stationary furnaces) incinera ted propert y *Assumed to be the same as the project A Crushing and sorting energy B polar powder (<1mm) (Rare metals) *Cementation when not valued as a rare metal. mixed metal (1 mm) (copper) exhaust fumes (containing hydrogen fluoride) Hydrogen fluoride treatment plant energy Figure 2-1. Baseline process (stationary furnace treatment) recycling process (this demonstratio n project). boundary Spent LIB packs Separation and D manual iro demoalluitmioi n n nmiu plastic Figure 2-2. industrial waste (raw fuel) Cement firing process therma D l energy gas Combustible exhaust C Roasting (containing hydrogen fluoride) burnt (roasting furneanceergsy) offering (i.e. religiou s D polar powder (<1mm) C (Rare metals) Crushing and *Cementation when not valued as a rare metal. sorting energy mixed metal (1 mm) (copper) animal sacrific e) Recycling process of this demonstration project 31 t-CO2/t 1.200 1.000 0.171 0.242 0.984 t-CO2/t-. 0.972 t-CO2/t-. LIB Pack LIB Pack 0.895 0.434 0.800 0.813 t-CO2/t-. 0.730 LIB Pack 0.600 0.400 0.461 0.200 0.000 Automotive 2 (domestic) baseline process Automotive 4 Mixed (wide (domeRseticc)ycling process of thveariety) project. Figure 2-3. Comparison of CO2 emissions per tonne by LIB pack 5,000 tCO2/year 4,000 3,000 2,000 1,000 697 4,016 t- CO2/year 3,319 4,309 1,073 t-CO2/year 3,236 4,093 1,986 t-CO2/ year (e.g. AD) 2,107 0 Figure 2-4. Automotive 2 (domestic) baseline Automotive 4 (domestic) Recycling of the Mixed (wide variety) process project process Comparison of CO2 emissions per unit of annual throughput by LIB pack 32 Table 2-3. CO2 emission reductions compared to the project and stationary furnace treatment (per tonne of LIB pack) Automotive 2 (domestic) Automotive 4 (domestic) Mixed (wide variety) process category (data ) item Cont ents emissi on (e.g. of CO2, etc.) t-CO2/t-LIB pack emissi on (e.g. of CO2, etc.) t-CO2/t-LIB pack emissi on (e.g. of CO2, etc.) t-CO2/t-LIB pack baseline process A process Incineration (stationary furnaces) Crushing and sorting 0.953 0.032 0.985 0.945 0.028 0.973 0.868 0.028 0.896 Iron, aluminium and plastics B recycling effect Rare metals, copper 0.001 0.000 0.001 0.001 0.001 0.001 0.001 0.000 0.001 27 C Recycling process of the project. Table 2-4. D process Roasting (roasting furnaces) Crushing and sorting Iron, aluminium and plastics COre2cyecmlinisgseioffnecrtedufclatmiomnsabcleomexphaaruesdt gas to the project Rare metals, copper CO2 reductions (A - B) - (C - D) process category (data Cont 0.822 0.032 0.854 0.001 a0n.0d4s0tationar0y.0f4u1rnace A0u.0to0m0otive 2 (domestic) emissi 0.171 on 0.740 0.028 0.768 0.001 0.037 treatment (per0y.0e3a8r of 0A.u0to0m1otive 4 (domestic) emissi 0.242 on 0.469 0.028 0.001 0.036 treatment) M0ix.0e0d0(wide emissi on 0.497 0.037 variety) 0.434 ) ents (e.g. of (e.g. of (e.g. of item CO2, CO2, CO2, etc.) etc.) etc.) 4,083 t/year 4,435 t/year 4,573 t/year t-CO2/year t-CO2/year t-CO2/year baseline process A process Incineration (stationary furnaces) Crushing and sorting 3,891 129 4,020 4,192 123 4,315 3,969 128 4,096 Iron, aluminium and plastics B recycling effect Rare metals, copper 3 2 3 1 4 3 6 03 Recycling process of the project. C process Roasting (roasting furnaces) Crushing and sorting Iron, aluminium and plastics D recycling effect flammable exhaust gas 3,357 129 3 164 3,487 167 3,282 123 2 164 3,405 169 2,147 128 3 164 2,274 167 Rare metals, copper 1 3 1 CO2 reductions (A - B) - (C - D) 697 1,073 1,986 Table 2-5. baseline process category NO Activity and CO2 emissions intensity of stationary furnace treatment (per tonne of 2 (domestic) LIB packs for on-board use) process activity level item numeri unit name cal value atomic unit name emission intensity numeric unit al value emission (e.g. of CO2, etc.) (tCO2/t) 1 Recycled heavy oil B consumption per Incineration (stationary furnaces) tonne of LIB pack 0.184 kL/t-LIB pack CO2 emission factor for the use of recycled heavy oil B. 3.000000 tCO2/kL 2 A Per tonne of LIB packs initially fed Amount of waste plastic treated in the process concerned. 0.158 t/t-LIB packs CO2 emission factors for the combustion of waste plastics. 2.550000 tCO2/t 0.551087 0.401881 3 Crushers (shearing type) Electricity consumption per tonne of LIB pack 44.443 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.022755 28 4 dust collector Baseline process recycling effectiveness. 5 Sorting (sifting) category NO process total amount iron recovery 1 (Crude steel alternative) aluminum recovery 2 (Aluminium recycled ingot substitute) plastic (plastics) recovery 3 (PP banding alternative). B lithium recovery 4 (Electric lithium alternative) cobalt recovery 5 (Electric cobalt substitute) Nickel recovery 6 (Electric nickel alternative) copper recovery 7 (Electrolytic copper alternative) Electricity consumption per tonne of LIB pack Electricity consumption per tonneacotifvLityIB pack level item name Iron recovery per tonne of LIB packs Amount of aluminium recovered from 1t of LIB packs Collected from 1t of LIB packs. plastic volume Amount of lithium recovered from 1 tonne of LIB packs Amount of cobalt recovered from 1t of LIB packs Amount of nickel recovered from 1t of LIB packs Amount of copper recovered from 1t of LIB packs 16.161 kWh/t-LIB pack 1.212 kWh/t-LIB pack numeri unit cal value 0.026 t/t-LIB packs 0.191 t/t-LIB packs 0.048 t/t-LIB packs 0.000 t/t-LIB packs 0.000 t/t-LIB packs 0.000 t/t-LIB packs 0.068 t/t-LIB packs CO2 emission factor for electricity use. 0.000512 tCO2/kwh CO2 emission factor for electricity useem. ission intensity atomic unit name 0.000512 tCO2/kwh numeric unit al value CO2 emissions per tonne of crude steel produced CO2 emissions per tonne of recycled aluminium ingot produced amount CO2 emissions per tonne of PP banded production. 0.001190 tCO2/t 0.003130 tCO2/t 0.000446 tCO2/t CO2 emissions per tonne of electric lithium production CO2 emissions per tonne of electrolytic cobalt production CO2 emissions per tonne of electrolytic nickel produced CO2 emissions per tonne of electrolytic copper produced 0.082300 tCO2/t 0.018800 tCO2/t 0.007980 tCO2/t 0.003670 tCO2/t 0.008274 0.000621 emission (e.g. of CO2,0e.9tc8.)5 (tCO2/t) 0.000031 0.000599 0.000021 0.000000 0.000000 0.000000 0.000251 total amount 0.001 Table 2-6 baseline process category NO Activity and CO2 emissions intensity of process item name stationary furnace treatment (per tonne of vehicle-mounted 4 (domestic) LIB packs) activity level numeri unit cal value atomic unit name emission intensity numerical unit value emission (e.g. of CO2, etc.) (tCO2/t) 1 Recycled heavy oil B consumption per tonne 0.169 kL/t-LIB pack Incineration (stationary furnaces) of LIB pack CO2 emission factor for the use of recycled heavy oil B. 3.000000 tCO2/kL 0.507282 2 A Per tonne of LIB packs initially fed Amount of waste plastic treated in the process concerned. 0.172 t/t-LIB packs CO2 emission factors for the combustion of waste plastics. 2.550000 tCO2/t 0.437878 3 Crushers (shearing type) Electricity consumption per tonne of LIB pack 38.859 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.019896 4 dust collector Electricity consumption per tonne of LIB pack 14.130 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.007235 5 Sorting (sifting) Electricity consumption per tonne of LIB pack 1.060 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.000543 total amount 0.973 29 Baseline process recycling effectiveness. category NO process iron recovery 1 (Crude steel alternative) aluminum recovery 2 (Aluminium recycled ingot substitute) plastic (plastics) recovery 3 (PP banding alternative). B lithium recovery 4 (Electric lithium alternative) cobalt recovery 5 (Electric cobalt substitute) Nickel recovery 6 (Electric nickel alternative) item name activity level Iron recovery per tonne of LIB packs numeri unit cal value 0.243 t/t-LIB packs Amount of aluminium recovered from 1t of LIB packs Collected from 1t of LIB packs. plastic volume Amount of lithium recovered from 1 tonne of LIB packs Amount of cobalt recovered from 1t of LIB packs Amount of nickel recovered from 1t of LIB packs 0.081 t/t-LIB packs 0.000 t/t-LIB packs 0.001 t/t-LIB packs 0.003 t/t-LIB packs 0.001 t/t-LIB packs atomic unit name emission intensity numerical unit value CO2 emissions per tonne of crude steel produced 0.001190 tCO2/t CO2 emissions per tonne of recycled aluminium ingot produced 0.003130 tCO2/t CO2 emissions per tonne of PP banded production 0.000446 tCO2/t CO2 emissions per tonne of electric lithium production CO2 emissions per tonne of electrolytic cobalt production CO2 emissions per tonne of electrolytic nickel produced 0.082300 tCO2/t 0.018800 tCO2/t 0.007980 tCO2/t emission (e.g. of CO2, etc.) (tCO2/t) 0.000289 0.000253 0.000000 0.000070 0.000051 0.000005 copper recovery 7 (Electrolytic copper alternative) total amount Amount of copper recovered from 1t of LIB packs 0.158 t/t-LIB packs CO2 emissions per tonne of electrolytic copper produced 0.003670 tCO2/t 0.000580 0.001 Table 2-7 baseline process category NO Activity and CO2 emissions intensity of stationary furnace treatment (per tonne of mixed (multi-species) LIB packs) process activity level item numeri unit name cal value atomic unit name emission intensity numeric unit al value emission (e.g. of CO2, etc.) (tCO2/t) 1 Recycled heavy oil B consumption per Incineration (stationary furnaces) tonne of LIB pack 0.164 kL/t-LIB pack CO2 emission factor for the use of recycled heavy oil B. 3.000000 tCO2/kL 2 A Per tonne of LIB packs initially fed Amount of waste plastic treated in the process concerned. 0.147 t/t-LIB packs CO2 emission factors for the combustion of waste plastics. 2.550000 tCO2/t 0.491999 0.375785 3 Crushers (shearing type) Electricity consumption per tonne of LIB pack 39.165 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.020052 4 dust collector Electricity consumption per tonne of LIB pack 14.242 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.007292 5 Sorting (sifting) Electricity consumption per tonne of LIB pack 1.068 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.000547 total amount 0.896 30 Baseline process recycling effectiveness. category NO process iron recovery 1 (Crude steel alternative) aluminum recovery 2 (Aluminium recycled ingot substitute) plastic (plastics) recovery 3 (PP banding alternative). B lithium recovery 4 (Electric lithium alternative) cobalt recovery 5 (Electric cobalt substitute) item name activity level Iron recovery per tonne of LIB packs Amount of aluminium recovered from 1t of LIB packs Collected from 1t of LIB packs. plastic volume Amount of lithium recovered from 1 tonne of LIB packs Amount of cobalt recovered from 1t of LIB packs numeri unit cal value 0.223 t/t-LIB packs 0.105 t/t-LIB packs 0.018 t/t-LIB packs 0.000 t/t-LIB packs 0.000 t/t-LIB packs atomic unit name emission intensity CO2 emissions per tonne of crude steel produced CO2 emissions per tonne of recycled aluminium ingot produced amount CO2 emissions per tonne of PP banded production. CO2 emissions per tonne of electric lithium production CO2 emissions per tonne of electrolytic cobalt production numeric unit al value 0.001190 tCO2/t 0.003130 tCO2/t 0.000446 tCO2/t 0.082300 tCO2/t 0.018800 tCO2/t emission (e.g. of CO2, etc.) (tCO2/t) 0.000265 0.000330 0.000008 0.000000 0.000000 Nickel recovery 6 (Electric nickel alternative) copper recovery 7 (Electrolytic copper alternative) total amount Amount of nickel recovered from 1t of LIB packs CO2 emissions per tonne of electrolytic copper produced 0.000 t/t-LIB packs 0.004 tCO2/t CO2 emissions per tonne of electrolytic nickel produced CO2 emissions per tonne of electrolytic copper produced 0.007980 tCO2/t 0.003670 tCO2/t 0.000000 0.000013 0.001 Table 2-8 Activity volume and CO2 emissions intensity of the Recycling process for demonstration projects. category NO process activity level item numeri name cal value project (per tonne of 2 (domestic) LIB packs for on-board use) emission emission intensity (e.g. of unit atomic numerica unit CO2, etc.) unit name l value (tCO2/t) 1 incinerator 2 C 3 ventilation fan Kerosene consumption per tonne of LIB pack Per tonne of LIB packs initially fed Amount of waste plastic treated in the process concerned. 0.153 kL/t-LIB pack 0.158 t/t-LIB packs Electricity consumption per tonne of LIB pack 77.593 kWh/t-LIB pack CO2 emission factor for paraffin use. CO2 emission factors for the combustion of waste plastics. CO2 emission factor for electricity use. 2.490000 tCO2/kL 2.550000 tCO2/t 0.000512 tCO2/kwh 0.380730 0.401881 0.039728 4 Crushers (shearing type) Electricity consumption per tonne of LIB pack 44.443 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.022755 31 5 dust collector Electricity consumption per tonne of LIB Recycling effectiveness of the recycling process in the pack demonstration project. 6 Sorting (sifting) category NO process Electricity consumption per tonnaecotivfitLyIB pack level total amount item name iron recovery 1 (Crude steel alternative) aluminum recovery 2 (Aluminium recycled ingot substitute) plastic (plastics) recovery 3 (PP banding alternative). Iron recovery per tonne of LIB packs Amount of aluminium recovered from 1t of LIB packs Collected from 1t of LIB packs. plastic volume 16.161 kWh/t-LIB pack 1.212 kWh/t-LIB pack numeri unit cal value 0.026 t/t-LIB packs 0.191 t/t-LIB packs 0.048 t/t-LIB packs D lithium recovery 4 (Electric lithium alternative) Amount of lithium recovered from 1 tonne of LIB packs 0.000 t/t-LIB packs cobalt recovery 5 (Electric cobalt substitute) Amount of cobalt recovered from 1t of LIB packs 0.000 t/t-LIB packs Nickel recovery 6 (Electric nickel alternative) Amount of nickel recovered from 1t of LIB packs 0.000 t/t-LIB packs copper recovery 7 (Electrolytic copper alternative) Amount of copper recovered from 1t of LIB packs 0.068 t/t-LIB packs CO2 emission factor for electricity use. CO2 emission factor for electricity eumseis. sion intensity atomic unit name CO2 emissions per tonne of crude steel produced CO2 emissions per tonne of recycled aluminium ingot produced amount CO2 emissions per tonne of PP banded production. CO2 emissions per tonne of electric lithium production CO2 emissions per tonne of electrolytic cobalt production CO2 emissions per tonne of electrolytic nickel produced CO2 emissions per tonne of electrolytic copper produced 0.000512 tCO2/kwh 0.000512 tCO2/kwh numerica unit l value 0.001190 tCO2/t 0.003130 tCO2/t 0.000446 tCO2/t 0.082300 tCO2/t 0.018800 tCO2/t 0.007980 tCO2/t 0.003670 tCO2/t 0.008274 0.000621 emission (e.g. of CO2, 0e.t8c.5)4 (tCO2/t) 0.000031 0.000599 0.000021 0.000000 0.000000 0.000000 0.000251 8 exhaust fumes total amount Replacement rate per tonne of LIB pack 0.017 t/t CO2 emission factor in coal (general coal). 2.330000 tCO2/t 0.040096 0.041 Table 2-9 Activity volume and CO2 emissions intensity of the Recycling process for demonstration projects. category NO process activity level item numeri name cal value project (per tonne of vehicle-mounted 4 (domestic) LIB packs) emission emission intensity (e.g. of unit atomic numerical unit CO2, etc.) unit name value (tCO2/t) 1 incinerator 2 C 3 ventilation fan Kerosene consumption per tonne of LIB pack Per tonne of LIB packs initially fed Amount of waste plastic treated in the process concerned. Electricity consumption per tonne of LIB pack 0.107 kL/t-LIB pack CO2 emission factor for paraffin use. 2.490000 tCO2/kL 0.265591 0.172 t/t-LIB packs 71.425 kWh/t-LIB pack CO2 emission factors for the combustion of waste plastics. CO2 emission factor for electricity use. 2.550000 tCO2/t 0.000512 tCO2/kwh 0.437878 0.036570 4 Crushers (shearing type) Electricity consumption per tonne of LIB pack 38.859 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.019896 5 dust collector Electricity consumption per tonne of LIB pack 14.130 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.007235 6 Sorting (sifting) Electricity consumption per tonne of LIB pack 1.060 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 0.000543 total amount 0.768 32 Recycling effectiveness of the recycling process in the demonstration project. category NO process item name activity level iron recovery 1 (Crude steel alternative) aluminum recovery 2 (Aluminium recycled ingot substitute) plastic (plastics) recovery 3 (PP banding alternative). lithium recovery D 4 (Electric lithium alternative) cobalt recovery 5 (Electric cobalt substitute) Iron recovery per tonne of LIB packs Amount of aluminium recovered from 1t of LIB packs Collected from 1t of LIB packs. plastic volume Amount of lithium recovered from 1 tonne of LIB packs Amount of cobalt recovered from 1t of LIB packs numeri unit cal value 0.243 t/t-LIB packs 0.081 t/t-LIB packs 0.000 t/t-LIB packs 0.001 t/t-LIB packs 0.003 t/t-LIB packs atomic unit name emission intensity CO2 emissions per tonne of crude steel produced CO2 emissions per tonne of recycled aluminium ingot produced CO2 emissions per tonne of PP banded production CO2 emissions per tonne of electric lithium produced CO2 emissions per tonne of electrolytic cobalt production numerical unit value 0.001190 tCO2/t 0.003130 tCO2/t emission (e.g. of CO2, etc.) (tCO2/t) 0.000289 0.000253 0.000446 tCO2/t 0.082300 tCO2/t 0.000000 0.000070 0.018800 tCO2/t 0.000051 Nickel recovery 6 (Electric nickel alternative) copper recovery 7 (Electrolytic copper alternative) 8 exhaust fumes total amount Amount of nickel recovered from 1t of LIB packs Amount of copper recovered from 1t of LIB packs Replacement rate per tonne of LIB pack 0.001 t/t-LIB packs 0.158 t/t-LIB packs 0.016 t/t CO2 emissions per tonne of electrolytic nickel produced CO2 emissions per tonne of electrolytic copper produced CO2 emission factor in coal (general coal). 0.007980 tCO2/t 0.003670 tCO2/t 2.330000 tCO2/t 0.000005 0.000580 0.036909 0.038 Table 2-10 Activities and CO2 emissions intensity of the Recycling process for demonstration projects. category NO process activity level item numeri name cal value project (per tonne of mixed (multi-species) LIB packs) emission intensity unit atomic numeric unit unit name al value 1 incinerator 2 C 3 ventilation fan Kerosene consumption per tonne of LIB pack Per tonne of LIB packs initially fed Amount of waste plastic treated in the process concerned. Electricity consumption per tonne of LIB pack 0.023 kL/t-LIB pack CO2 emission factor for paraffin use. 0.147 t/t-LIB packs CO2 emission factors for the combustion of waste plastics. 69.273 kWh/t-LIB pack CO2 emission factor for electricity use. 2.490000 tCO2/kL 2.550000 tCO2/t 0.000512 tCO2/kwh 4 Crushers (shearing type) Electricity consumption per tonne of LIB pack 39.165 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 5 dust collector Electricity consumption per tonne of LIB pack 14.242 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh 6 Sorting (sifting) Electricity consumption per tonne of LIB pack 1.068 kWh/t-LIB pack CO2 emission factor for electricity use. 0.000512 tCO2/kwh total amount emission (e.g. of CO2, etc.) (tCO2/t) 0.058160 0.375785 0.035468 0.020052 0.007292 0.000547 0.497 33 Recycling effectiveness of the recycling process in the demonstration project. category NO process item name activity level iron recovery 1 (Crude steel alternative) Iron recovery per tonne of LIB packs numeri unit cal value 0.223 t/t-LIB packs aluminum recovery 2 (Aluminium recycled ingot substitute) Amount of aluminium recovered from 1t of LIB packs 0.105 t/t-LIB packs plastic (plastics) recovery 3 (PP banding alternative). D lithium recovery 4 (Electric lithium alternative) Collected from 1t of LIB packs. plastic volume 0.018 t/t-LIB packs Amount of lithium recovered from 1 tonne of LIB packs 0.000 t/t-LIB packs atomic unit name emission intensity CO2 emissions per tonne of crude steel produced CO2 emissions per tonne of recycled aluminium ingot produced amount CO2 emissions per tonne of PP banded production. CO2 emissions per tonne of electric lithium production numeric unit al value 0.001190 tCO2/t 0.003130 tCO2/t 0.000446 tCO2/t 0.082300 tCO2/t emission (e.g. of CO2, etc.) (tCO2/t) 0.000265 0.000330 0.000008 0.000000 cobalt recovery 5 (Electric cobalt substitute) Nickel recovery 6 (Electric nickel alternative) copper recovery 7 (Electrolytic copper alternative) 8 exhaust fumes total amount Amount of cobalt recovered from 1t of LIB packs Amount of nickel recovered from 1t of LIB packs Amount of copper recovered from 1t of LIB packs Replacement rate per tonne of LIB pack 0.000 t/t-LIB packs 0.000 t/t-LIB packs 0.037 t/t-LIB packs 0.015 t/t CO2 emissions per tonne of electrolytic cobalt production CO2 emissions per tonne of electrolytic nickel produced CO2 emissions per tonne of electrolytic copper produced CO2 emission factor in coal (general coal). 0.018800 tCO2/t 0.007980 tCO2/t 0.003670 tCO2/t 2.330000 tCO2/t 0.000000 0.000000 0.000136 0.035797 0.037 data item Table 2-11. List of sources of emission factors used in the estimation of CO process CO2 emissions per tonne of crude steel produced Iron recovery (crude steel replacement) CO2 emissions per tonne of recycled aluminium ingot produced Aluminium recovery (recycled aluminium ingot substitute) CO2 emissions per tonne of electrolytic copper produced Copper recovery (electrolytic copper replacement) CFP Programme 'Database of common intensity of CO2 conversion'. CO2 emissions per tonne of electric lithium produced Lithium recovery (electric lithium replacement) CO2 emissions per tonne of electrolytic cobalt production Cobalt recovery (electro-cobalt substitution) CO2 emissions per tonne of electrolytic nickel produced Nickel recovery (electro-nickel substitution) CO2 emissions per tonne of PP banded production. Plastic recovery (alternative to PP banding) CO2 emission factor for the use of recycled heavy oil B. CO2 emission factor for paraffin use. Incineration (stationary furnaces) incinerator Ministry of the Environment, 'List of calculation methods and emission factors in the calculation, reporting and publication system'. 34 CO2 emission factor for electricity use. ventilation fan Crushers (shearing type) dust collector Sorting (sifting) 'List of emission factors by electric utility (H29 results alternative values)' - H29 results Published by the Ministry of the Environment and the Ministry of Economy, Trade and Industry on 27.12.H30. CO2 emission factors for the combustion of waste plastics. Incineration (stationary furnaces) incinerator Ministry of the Environment, 'List of calculation methods and emission factors in the calculation, reporting and publication system'. Coal (general coal) Calories exhaust fumes Coal ash handbook H28. 2.3 Study of CO2 emissions from the collection of used LIB packs A model case was also set up to calculate the amount of CO The calculation range was defined as the period from the disposal of the vehicle at the dealership to the vehicle dismantler, w h e r e t h e LIB packs are removed and taken to a manual dismantling yard. For the loading situation during transport, two patterns were set up: ideal loading and inefficient loading . The closest to the current reality is the inefficient loading one. As for the vehicles to be transported, a 9-tonne trailer was set for transport 1), which is brought from the dealer to the auto dismantler, and for transport 2), which is brought from the auto dismantler to the manual dismantling yard, a 2-tonne truck and a 4-tonne truck were used Two patterns were set for transport 2). As a result of the calculation using the improved ton-kilometre method, CO2 emissions per tonne of LIB packs were reduced t o about 50 kg under ideal loading, but 128 kg and 167 kg under the current inefficient loading, which is almost the same as the CO2 emissions for processing a single type of LIB packs. Draft model for studying CO2 emissions from LIB pack collection. area of study (investiga tion) ELV Place of discharge (Dealer). disposal Sco pe of calc ulati on cargo id transpor ELV ea t l (i) lo transpor ad t LIB Pack (ii) *LIB packs for transport. Calculate the amount of CO Transpor t . transport vehicle automobil e demolition condtirsamctaonrtli ng LIB pack loading conditio ns 6 ELVs per trailer. (6 LIB packs) LIB Pack LIB pack LIB pack (2) Transpor tation waste disposal dismantlin g by hand LIB module Other. torrefa ction loadin g capaci ty mileage 6 units 50 km Maximum loading on transport vehicles (4t, 2t) *1 4t: max 50 pcs. 2t: 25 max. 100 km in effi ci en t pr od uc t 10^4 4 transpor ELV t (i) transpor LIB Pack t (ii) 1 ELV per trailer. (1 LIB pack) one (object) Minimum loading on transport vehicles 4t: 1 pc. 2t: 1 piece (4t, 2t) *2 50 km 100 km *1: Maximum loading capacity taking into account pallet size and safe transport configuration; LIB packs are assumed to be of medium size. *2: This is set as the minimum loading capacity, as car dismantlers do not have a covered storage area and therefore carry out the removal from one vehicle. Figure 2-5. Model to study CO2 emissions from the collection of used LIB packs (Remark: assuming ELVs 1.5 t/unit and LIB packs 50 kg/unit) 35 CO2 emissions per tonne of used LIB packs collected (t-CO2/t-LIB pack) 0.200 0.167 0.150 0.128 0.100 0.050 0.027 0.048 0.000 Transport (1) - 9t + Transport (2) - 4t Transport (1) - 9t + Transport (2) - 2t Transport (1) - 9t + Transport (2) - 4t ideal load Haulage (1) - 9t + Haulage (2) - 2t inefficient loading Figure 2-6. CO2 emissions from the collection of used LIB packs 36 Table 2-12. Basis for calculation of CO2 emissions from collection of used LIB Ideal loading packs category process Activities /units of activity reference number data item numeric unit al value Formula, description. Transport . 9t trailer category Transport . activity level intensity intensity C001 C002. ELV loading weight of trucks (trailers) ELV loading rate of trucks (trailers) LIB packs as a percentage of the loaded weight of the truck (trailer) Volume of transport of Transit Distance Quantity transported per tonne of ELV CO2 emissions intensity of diesel oil Fuel (diesel) consumption per tkm process Activity/. intensity reference number data item 9 t/unit. 100%. %/unit 0.3 t/unit. 50 km/turn 450 tkm 2.5800 tCO2/kL 0.039 L/tkm numeric unit al value 1.5t x 6 vehicles 6 units/unit 50 kg/unit x 6 units movement within the prefecture Loaded weight x transport distance Emissions intensity Median 9t vehicle, 100% load factor Formula, description. Transport (ii) 4t truck. (2) Transportatio n activity level intensity intensity C001 C002. Truck (4t) LIB pack loading weight Truck loading rate Transit Distance Quantity transported per tonne of ELV CO2 emissions intensity of diesel oil Fuel (diesel) consumption per tkm 2.5 t/unit. 63%. %/unit 100 km/turn 250 tkm 2.5800 tCO2/kL 0.0867 L/tkm Prerequisite. 4t movement within the prefecture Loaded weight x transport distance Emissions intensity Median 5t vehicle, 60% load factor sourc e (e.g. quota tion) estimated value estimated value estimated value estimated value 1) 2) sourc e (e.g. quota tion) estimated value estimated value estimated value 1) 2) category process Activity/. intensity reference number data item Transport (ii) 2t truck (2) Transportatio n activity level intensity intensity C001 C002. Truck (2t) LIB pack loading weight Truck loading rate Transit Distance Quantity transported per tonne of ELV CO2 emissions intensity of diesel oil Fuel (diesel) consumption per tkm numeric unit al value Formula, description. 1.0 t/unit. 50%. %/unit 100 km/turn 100 tkm 2.5800 tCO2/kL 0.1680 L/tkm Prerequisite. 2t movement within the prefecture Loaded weight x transport distance Emissions intensity Median 3t vehicle, 40% load factor sourc e (e.g. quota tion) estimated value estimated value estimated value 1) 2) inefficient category category process process Activity/. intensity Activity/. intensity reference rneufemrebnecr e number data item data item Transpor Tt (riai)n4stport . truck. 9t trailer (2) TTrraannssppoorrtt atio. n activity level intensity intensity category process activAiitnyctetleivnvisetyitly/. intensity intensity Truck (4t) LIB pack loading weight ETLruVcklolaodaindginwgeriagthet of trucks (trailers) ETLraVnlosaitdiDngisratatenocfetrucks (trailers) C001 C002. LQIBuanstaitypterarcnesnptaogrteedofptheer tloandneedowf eEigLhVt of the tCruOck2(teramiliesrs) ions intensity of diesel oil VFouleulm(deieosf peal)cckosntrsaunmsptoiortnedp.er tkm Transit Distance Cre0fe0r1ence Quantity transporteddpaetar tiotenmne of ELV CO2 emissions intensity of diesel oil Cnu0m02b.er Fuel (diesel) consumption per tkm Transpor t (ii) 2t truck (2) Transport ation activity level intensity intensity C001 C002. Truck (2t) LIB pack loading weight Truck loading rate Transit Distance Quantity transported per tonne of ELV CO2 emissions intensity of diesel oil Fuel (diesel) consumption per tkm numeri unit ncaulmeri unit cval ue value 0.05 t/unit. 1%.5. t%/u/nuitn. it 1170%0. %km/u/ntuitrn 5 tkm 2.508.0050 tt/CunOit.2/kL 0.3710 L/tkm 50 km/turn nume7r5i tkm unit 2.5800 tCO2/kL c0a.l2530 L/tkm value 0.1 t/unit. 3%. %/unit 100 km/turn 5 tkm 2.5800 tCO2/kL 0.5190 L/tkm Formula, description. Formula, description. Prerequisite. 14t.5t x 6 vehicles 6muonveitsm/uennit within the prefecture Loaded weight x transport distance 5E0mkisgs/iuonnsit ixnte1nusnitiyt Median 5t vehicle, 10% load factor movement within the prefecture Loaded weigFhotrmx utrlaa,ndsepsocrrtipdtiiosnta. nce Emissions intensity Median 9t vehicle, 10% load factor Prerequisite. 2t movement within the prefecture Loaded weight x transport distance Emissions intensity Median 3t vehicle, 10% load factor source s(eo.ugr.ce (qeu.go.tatio qnu) otatio evastlunime) ated estimated value estimated value e1s)timated v2a) lue estimated value source 1) 2) (e.g. quotatio n) estimated value estimated value estimated value 1) 2) (Remark: emission factors etc. Source: below. 1) Ministry of the Environment, 'List of calculation methods and emission factors for calculation, reporting and publication systems (Reference 1)'. 37 2) Ministry of Economy, Trade and Industry (METI), Ministry of Land, Infrastructure, Transport and Tourism (MLIT), 'Joint Guidelines for Calculating CO2 Emissions in the Logistics Sector Ver. 3.1 (July 2016)') 38 2.4 Study of the effect of reducing environmental impact due to exhaust emissions. Exhaust gases (containing hydrogen fluoride)Low-cost detoxification treatmentThe behaviour of halogen elements(fluorine) in LIB packs was verified, and most of them were transferred to the polar powder less than 1 mm . Some of it was transferred to the roasting exhaust gas, but this exhaust gas is sent to the cement calcination furnace for detoxification treatment. The results of the measurement of the final exhaust gas from the cement calcination plant confirmed the fluorine detoxificatiLoIBnMpodruolecess. torref actio Fluorine matebara n (species of yerba mate) (by input LIB module) For invehicle use (Domestic)1 For invehicle use (Domestic)2 For invehicle use (Outside the country)3 For invehicle use (Domestic)4 for stationary use (Domestic) mixture (multispecies) burnt offerin g (i.e. Crureslhiignigoand us soratninigma l sacrifi ce) <1 mm (Active substance ) 100 exh1a0u0 100 st fumes For in- vehicle use Analysis of final exhaust gas confirm(Deodmtehsatitci)t1 was ND. (e.g. adsorption on clinker) 5 100 100 100 For invehicle use (Domestic)2 1 For invehicle use (Outside the country)3 4 For invehicle use (Domestic)4 3 for stationary use (Domestic) 2 mixture (multispecies) 20 To cement firing process *Last year's data: vehicle-mounted (domestic): 2, vehicle-mounted (international): 10. 1 mm For invehicle use (Domestic)1 95 For invehicle use (Domestic)2 99 For invehicle use (Outside the country)3 96 For invehicle use (Domestic)4 97 for stationary use (Domestic) 98 mixture (multispecies) 80 For invehicle use (Domestic)1 0 For invehicle use (Domestic)2 0 For invehicle use (Outside the country)3 0 For invehicle use (Domestic)4 0 for stationary use (Domestic) 0 mixture (multispecies) 0 Figure 2-7. Material balance of fluorine in the project 39 3. Verification of project feasibility through economic feasibility assessment 3.1 Economic evaluation of used LIB packs under the project scheme. per tonne of LIB packs The results of the balance of payments based on resource assessment and cost assessment are shown. From the material balance by LIB module, lithium recovery efficiency at less than 1mm was good (2 for automotive/domestic), bad (4 for automotive/domestic), mixed (various types) 3 Estimates were made in the case. As a result of the trial calculation, Co a n d Ni in the automotive 4 pole powder (<1mm) were evaluated as valuable. On the other hand, neither the 2 pole powders for automotive use nor the mixed pole powder (<1 mm) were valorised and were judged to be used as cement raw materials. The value of the rare metals in vehicle-mounted 4 was calculated to be about 40,000/t, but the cost of such as labour costs is expected to be about 180,000/t, resulting in a balance of -130,000/t. In last year's result, the overall evaluation was expected to be around 100,000 , but in this project it was calculated to be around 150,000 . This is thought to be due to the different material composition ratio of LIB packs , which changed the cost calculation result. In particular, when the amount of base metal in LIB packs decreased and the amount of LIB modules increased, LIB module transportation costs and roasting treatment costs increased, resulting in an overall increase in costs. The knowledge that the cost of LIB packs for vehicle-mounted LIBs varies greatly depending on the type of LIB, should be reflected in the setting of costs in actual operation. The reduction in paraffin consumption this year was expected as a result of the demonstration results. Based on this reduction effect, we compared the economic evaluation of last year's LIB packs and modules before and after, and calculated that a cost reduction effect of 2,000/t could be achieved. We would like to continue to examine measures to reduce equipment costs and consumables costs for better economic evaluation. Table 3-1. cost (Unit: yen/t) Overall economic evaluation of used LIB modules by type of resource value and scrap metal iron non-ferrous (H2) (Aluminium Gala) plastic <1 mm 1 mm Li. Co Ni. Rare metal actual recovery resource cost account comprehensi Cu assessment ve decisions amount total evaluation Automotive 2 Automotive (domestic) - EVs LIBs 570 22,000 -4,780 x- x- x- x- -5,600 9,990 22,160 -185,500 -163,000 mark mark ma mar (use (use rk k d to d to (us (use indic indic ed d to ate ate to indic (Remarks: an an indi incor incor cat ate an Resources recovered by manual dismanretlcint grwecetre qeuotedinacsoH2 for ferrous metals and aluminium galas for non-ferrous metals, while plastaicnsswwaenreswrecayncled inrrevciet w of the current situation. er in er in inc ans <1mm w a s assumed to be smelted at Co anad Ni a coorrntent w coenrcentrations, and Li was also recovered if test, test, ect either one was valued. (From smelting heeatcr.i)ngest)c..) an in a test, sw etc.) er 40 in a tes t, etc .) Automotive 4 (domestic) - HV 5,330 9,300 0 Fat. Fat. Fat . Fat. 5,500 22,730 42,960 -173,100 -130,000  Li, Co, Ni F o r metal values, LME market valuation was used for Co a n d Ni (smelting costs taken into account); Li was excluded from the monetary valuation for the above setting reasons. (From smelting hearings) If the concentration was not assessed as valuable but metal recovery was possible, the material was classified as low-value valuable, and if the concentration was such that metal recovery was not possible, the material was classified as cemented (treatment costs required). 1 mm was defined as copper assessment (iron and aluminium mixed) and the assessed amount was the amount of copper contained in the 1 mm recovered amount, not the 1 mm recovered amount. In terms of costs, labour costs, transport costs (modules, packs and roasting materials), equipment costs and consumables costs were considered. In the table above, base metals and plastics are in the last digit, rare metals and costumers are in the last two digits, and overall ratings are in the last two digits. 3 d i g i t s truncated). 41 Table 3-2. Breakdown of total costs in spent LIB pack disposal schemes (Unit: Yen) labour cost transportatio equipment Consumables n costs cost costs Automotive LIBs Automotive 2 (domestic) - EVs Automotive 4 (domestic) - HV -62,700 -57,700 -82,300 -78,000 -32,000 -29,400 -8,400 -7,900 Mixed (wide variety) -55,900 -77,300 -29,000 -7,800 Table 3-3. Comparison of the composition of used LIB packs and overall assessment of income and expenditure for this year and last year H30. (Unit: yen/t) For invehicle use LIB Automotive 2 (domestic) - EVs Automotive 4 (domestic) - HV Mixed (wide variety) Unit: t pack LIB Module scrap metal iron Non- ferrous*. plastic burnt offering (i.e. <1 mm 1 mm religious animal scrap metal plastic Firoornin- Auntoomn-ofetrirvoeus2 1 v(Heh2ic)le (do(Amluemstiinci)u-mEVs Li. Co use AutomGoatlaiv)e 4 1 LIB (domestic) - HV Mixed (wide variety) 1 570 22,000 -4,780 x x - - <1 mm 1 mm 0.7r3are metal 0.03 0.19 Ni. actual Cu recovery 0.68judgment0.24amount0.08 sacrifice) 0r.e0s5ource0.58 cost 0.23 assessment account 0.00 0.50 0.06 total comp0r.3eh5e nsive 0.44 evaluatio 0.66 0.22 0.11 x x-mark -5,600 - (used to 0.02 0.51 0.16 n 0.35 9,990 22,160 -185,500 -163,000 m ma ma indicate an ar rk rk incorrect k (us (us answer in (u ed ed a test, etc.) se to to d ind ind to ica ica in te te dic an an at inc inc e orr orr an ect ect inc an an orr sw sw ec er er t in in an a a sw tes tes er t, t, in etc etc a .) .) te st, et c.) 5,330 9,300 0 F Fa Fa at. t. t. Fat. 5,500 22,730 42,960 -173,100 -130,000 4,900 12,107 -1,779 x x x x-mark -5,600 - - - (used to 4,930 14,540 -170,200 -155,000 m ma ma indicate an ar rk rk incorrect k (us (us answer in (u ed ed a test, etc.) se to to d ind ind to ica ica in te te dic an an at inc inc e orr orr an ect ect inc an an orr sw sw 42 ec er er t in in an a a sw tes tes er t, t, in etc etc a .) .) te st, et c.) H29 Unit: t pack LIB Module scrap metal iron Non- ferrous*. plastic burnt offering (i.e. <1 mm religious Cases with cost estimates based on H29 assumptions scrap mFoetrainl - Domesti c - HV 1 0.43 0.32 <1 mm (Unit: yen/t) iron vehnicolne-ferroOusutside plastic 1 0.59 rare me0ta.l02 the Li. Co Ni. (H2) use(Aluminciuomuntry - recovery LIBGala)AveHrVage- 1 judgment 0.51 0.17 Domesti 6,980 23,73H0V -4,760 Fat. Fat. x- Fat. For in- c - HV for stationary - ma 1 - vehicle use rk use (us LIB ed to ind ica te an inc orr ect an sw er in a tes t, etc .) Outside 470 40,000 -4,340 x- x- x- x- the mark mark ma mark country - (used (use rk (used HV to d to (us to indica indic ed indicate te an ate to an incorr an ind incorre ect incor ica ct answ rect te answer er in ans an in a a wer inc test, test, in a orr etc.) etc.) test, ect etc.) an sw er in a tes t, etc .) Average- 3,730 31,860 -4,550 Fat. Fat. x- Fat. HV ma rk (us ed to ind ica te an inc orr ect an sw er in a tes t, animal 0.21 0.05 sacrifice) 0.33 0.35 1 mm 0.0r4esource0.45 actual total assessmen amount (Cu) 0.28 0.0t5total 0.39 16,200 - 17,120 - 59,340 0.80 -1,100 16,850 51,800 0 16,990 48,030 0.05 cost 0.08 account 0.06 -128,100 0.20 -158,700 -143,400 1 mm total 0.28 comp0re.3h8en sive evalua0t.3io3n -68,000 0.60 -106,000 -95,000 43 etc .) Stationary LIB - - - Fat. Fat. Fa Fat. 0 100 100 -186,500 -186,000 t. Cases with cost estimates based on H30 assumptions. (Unit: yen/t) For invehicle use LIB Domesti c - HV Outside the country HV AverageHV Stationary LIB scrap metal iron (H2) non-ferrous (Aluminium Gala) 6,980 23,730 470 40,000 3,730 31,860 - - plastic Li. Co <1 mm Ni. rare metal recovery judgment actual amount 1 mm total (Cu) resource assessment total cost account -4,760 -4,340 -4,550 - F at. x m ar k (u se d to ind ica te an inc orr ect an sw er in a tes t, etc .) F at. F at. Fa x- Fat. t. mark (use d to indic ate an incor rect answ er in a test, etc.) x x- x-mark - mark (used to ma (use indicate rk d to an (us indic incorrect ed ate answer to an in a test, ind incor etc.) ica rect te answ an er in inc a orr test, ect etc.) an sw er in a tes t, etc .) Fa xt. mark (use d to indic ate an incor rect answ er in a test, etc.) Fa Fat. t. Fat. Fat. 16,200 -1,100 0 0 17,120 16,850 16,990 100 59,340 -126,800 51,800 -156,900 48,030 -141,900 100 -183,500 comprehen sive evaluation -67,000 -105,000 -93,000 -183,000 *Each resource assessment in H29 has been revised to align with the unit costs in H30. 44 3.2 Verification of the possibility of improving the economic efficiency of used LIB packs by reviewing and improving the project scheme. Used LIB packs Resource value and processing cost Comprehensive evaluation of economic efficiency was carried out by reviewing and improving the scheme to reduce costs and verifying the possibility of economic efficiency improvement. Scheme Review and Improvement As methods, estimates were made for each of the two methods: reducing treatment costs by expanding the scale of treatment, and reducing transport costs by consolidating treatment functions and reducing the number of transports. As a result of the trial calculation, in the case of pattern (2) , the cost is expected to be reduced to around -100,000 at a treatment scale of 30 t/day. In the case of the final target of a fully integrated facility (Pattern 3) , the cost is expected to be less than 100,000 yen from a scale of 20t/day. In order to set a more realistic cost setting for recycling, it is necessary not only to improve technological development , but also to design a concept for the consolidation of bases and to improve the collection capacity so that the scale can be expanded smoothly after practical implementation. no longer used LIB Pack Pattern (i). Separation and manual demolition Dismantle d LIB modules torref actio n 10-60 t/day burnt offering (i.e. religious animal sacrifice) crushing selection Pattern (ii). no longer used LIB Pack Separation and manual demolition Dismantle d LIB modules torrebf urnt offering (i.e. religious animal sacrificec)rushing 10a-c6t0io t/day n selection Pattern (iii). no longer used LIB Pack Figure 3-1. Separation and manual Dismantled LIB module torref 10a-6ct0io t/day burnt offering (i.e. crushing selection demolition n religiou s animal sacrifice Conveyance patterns in the economic evalua)tion study of the project Table 3-4. Comparison of overall economic evaluation of spent LIB pack treatment by improving the scale of treatment and number of transports processi 10 ng scale t/day transportation pattern 1 2 3 20 t/day 1 2 3 (Unit: yen/t) 30 t/day 1 2 3 Automotive LIBs Automotive 2 (domestic) - EVs Automotive 4 (domestic) - HV Mixed (wide variety) -163,000 -146,000 -118,000 -138,000 -121,000 -94,000 -129,000 -112,000 -84,000 -130,000 -115,000 -89,000 -107,000 -92,000 -67,000 -98,000 -83,000 -58,000 -155,000 -140,000 -115,000 -133,000 -118,000 -93,000 -125,000 -109,000 -85,000 45 processi ng scale transportation pattern Automotive LIBs Automotive 2 (domestic) - EVs Automotive 4 (domestic) - HV Mixed (wide variety) 1 -127,000 40 t/day 2 -110,000 3 -82,000 50 t/day 1 2 -123,000 -106,000 3 -78,000 1 -123,000 60 t/day 2 -105,000 3 -78,000 -97,000 -82,000 -56,000 -93,000 -78,000 -52,000 -92,000 -77,000 -52,000 -123,000 -108,000 -83,000 -119,000 -104,000 -79,000 -119,000 -104,000 -79,000 46 3.3 Model studies to reduce transport costs The transportation costs of used LIB packs were verified in a more detailed model case using the aforementioned pattern (2) model. The specific area images, loading capacity and mileage areshown below. [5] to [8] correspond to the ideal loading capacity model. As a result of the trial calculation, the model with the lowest transportation costs was [5] , which was collected and dismantled in the Nagoya area, where the distance travelled was also small, and transported to Tsuruga. The model also showed that there was almost no difference in cost between the Tsuruga delivery and the Nagoya delivery. LIB packs Processing costs Transportation costs account for more than 1/3 of the processing costs Selection of sites Consideration should be given to. Pattern (ii). auto dismantler occurred in no longer used LIB Pack Separation and manual demolition Dismantled LIB modules torrefa ction burnt offering (i.cer.ureslhiginious ansimealelctio sacrifice) g n 10 t/day Roasting, crushing and sorting demolition yard Collection area Transport 1 cargo tra ns LIB Pack po rt 1 transport vehicle 4t truck tra LIB ns po module rt 2 8-tonne truck Transport 2 loading loading conditions capacity minimum loading 50 kg (1 piece) maximum payload 2,500 kg (50 pieces) maximum payload 3,500 kg (100 pcs) Mileage Patterns 50 km (e.g. metropolitan area Iruma, Nagoya area) 350 km (e.g. metropolitan area Nagoya area) 100 km (e.g. around Nagoya Tsuruga) 450 km (e.g. Iruma to Tsuruga, Nagoya area to Hiroshima area). Figure 3-2. Model for reducing transport costs in the project Table 3-5. Comparison of area image and cost of transporting used LIB packs by transport patte Example of area image Trans coponrtd1ition Trans port 2 rn Collec Roastin mileage tion demolition g, Loading Distance Loading (km) area yard crushing capacity (kg) travelled (km) capacity (kg) and sorting facility Transport costs per tonne of LIB packs (Yen/t-LIB pack) [1] Nagoya Nagoya Tsuruga 50 50 3,500 100 535,320 area area era (1185.8.2 8- 1190.4.1 1) [2] the capital bay Tsuruga 50 50 3,500 450 552,980 city (often era (Note: TTohkeyoh) aareualage vehicles we(1r1e85d.8e.2fined as haulage 1: 4-tonne trucks and haulage 2: 8-tonne trucks. The (typically 8- haulagewitchions50tskmwere set at marke11t9u0n.4i.t1prices by vehicle type and distance travelled. The LIB paofcckityc'sonversion was calcu1l)ated based on the ratio of this year's demonstration project Mixed centre) [3] the capital city (often Nagoya area Tsuruga era 50 47 350 3,500 100 1,435,320 Tokyo) area (1185.8.2 (typically 8- within 50 km 1190.4.1 of city's 1) centre) [4] the capital Nagoya Tsuruga 50 350 3,500 450 1,452,980 (multispecies) The LIB pack weight wassetat50 kg/unit). 48 4. Business feasibility of this treatment technology. 4.1 Forecasted market size of waste to be received. As shown in the table below, it is assumed that the processing needs for automotive and stationary lithium-ion batteries will increase in all parts of Japan from 2020 onwards, and in order to meet these needs properly, a recycling system that can make effective use of existing infrastructure in various parts of Japan and respond quickly and economically according to processing needs is required. The system is based on the concept of a recycling system that can respond quickly and economically to the processing needs of each region. This system is considered to make a significant contribution to a recycling-oriented society in the future, as it can reduce the cost of collecting used LIB packs and modules and respond flexibly to the volume of treatment consigned, by using cement plants located in various parts of Japan in a phased manner. Figure 4-1 Projected disposal of automotive LIBs (Source: Japan Automobile Manufacturers Association, "Next Generation Vehicles Appropriate Treatment and Recycling Status of Efforts", 2018 Sangyo Kaikan and Chukan Kaikan Joint Conference Document Document 3-2 (4 September 2018)). 49 Figure 4-2 Market size forecast for stationary LIBs (Source: Seed Planning HP, press release 17 April 2017. (https://www.seedplanning.co.jp/press/2017/2017041701.htm) 50 4.2 Horizontal expansion to its own existing facilities In this scheme, demonstration tests were conducted on LIB packs for vehicle-mounted vehicles, which are difficult to dismantle because they are robust and of unspecified size and are expected to generate a particularly large amount of LIB packs but it is technically possible to process stationary LIB modules as well. Furthermore, not only large but also small LIBs can be processed, and a wide range of LIB packs and modules for various applications distributed in Japan are planned to be accepted, not limited to those for vehicle-mounted LIBs. The scheme will also achieve low-carbon recycling through the efficient use of waste heat energy by installing a dedicated treatment plant for used LIB packs and modules within the cement plant. . Not only at Tsuruga Cement's Tsuruga Plant, where the demonstration tests are being conducted, but also at each of the Group's cement plants (see diagram below), taking into account the LIB pack module collection system, and planning to introduce and deploy the system in stages. Furthermore, the system can also be deployed at overseas cement production sites, and the possibility of overseas deployment is also being considered. Figure 4-3. Pacific Cement's cement business locations in Japan (Source: Pacific Cement Corporation HP http://www.taiheiyo-cement.co.jp/company/busi/world/japan-2.html) (Remark: in the figure, blue characters indicate the Pacific Cement plant and black characters indicate the plants of Group companies). 51 4.3 Advantages of the Project. As for the LIB recycling treatment system, in addition to this system (cement calcination + rotary bed continuous roasting furnace) there are also kiln incineration/roasting furnaces, fixed incineration/roasting furnaces, melting furnaces and electric furnaces. The advantages and disadvantages of the main treatment systems are shown in the table below. Table 4-1. Advantages and disadvantages of different treatment systems processing Benefits. demerit system main, primary system (Cement fired) (+ rotary floor continuous roasting furnace) Continuous processing (greater throughput and lower energy costs). Cement calcination furnaces under high calcium for the treatment of roasting exhaust gases containing fluorine are inexpensive. Roasting temperatures can be controlled and all base and rare metals can be Difficult to process in packs and need to be dismantled down to the module. separated and recovered. Energy saving and low CO2 emissions can be achieved by using the exhaust heat from the cement calcination process and the heat content of the LIB (residual power and combustible content) as a heat source for the roasting process. ... roasting exhaust gases can be used as heat in the cement calcination process. ... because the residues can be converted into cement resources, 100% recyclable. Retrofitting of existing cement production facilities. be able to install Rotary kiln type Incinerators/r oasting furnaces Continuous processing (large processing capacity, (Energy costs can be reduced). ...usually the inner walls of the kiln have to be dismantled down to a single cell. Difficult to process packs/modules direct feeding process due to damage Low recyclability of useful metals etc. as they are mixed with a wide variety of waste batteries and waste materials and are contaminated. Costly treatment of fluorine-containing flue gases fixed type Incineration/roastin g furnaces ...packs can be processed as they are. Some facilities can be converted from existing low-concentration PCB treatment furnaces at inexpensive The number of people who have been treated in a batch process is not continuous (treatment). (Smaller capacity to reason) When disposed of as packs, the pre- conversion costs. dismantled recovered materials are also incinerated, resulting in a low recycling rate. 52 Costly treatment of fluorine-containing flue gases melting furnace Continuous processing. ...packs can be processed as they are. Energy (electricity) costs are generally high. The melting process at high temperatures makes it difficult to separate and recover As shown in Table 4-1 , this system (cement calcination + rotary bed continuous roasting furnace) is likely to be cheaper than other treatment systems, as it is easy to increase the treatment volume due to its continuous treatment capability, low energy cost and significant cost reduction in treating exhaust gas containing harmful substances. In addition, the system can be retrofitted to existing cement plants, making it easy to establish a business by utilising the many cement plants located in Japan and abroad as LIB roasting treatment bases, and so on. In the future, the rotary bed continuous roasting furnace basket etc. will be modified, and LIB packs will be collected and transported. We will strive to make our pricing more competitive by promoting improvement studies. 53 5. Future challenges and business plans 5.1 Future tasks. LIB packs/modules have a wide variety of structures and material compositions. When roasting tests were conducted for each type of LIB module in this year's demonstration experiment, differences in resource recovery rates were observed. In actual operation, it is necessary to utilise the data accumulated in this demonstration and adjust the roasting conditions to increase the resource recovery rate. In order to put this project scheme into practical use, it is necessary to improve the packing and handling equipment and basket structures used in the collection, dismantling, roasting, crushing and sorting processes in order to make the work more efficient and labour-saving. Roasting furnace We would like to examine structural improvement proposals that would increase processing capacity, improve energy efficiency and reduce processing costs , and for those improvement proposals that are considered to be cost-effective , we would like to make prototypes and verify their productivity . In order to further improve the economic evaluation in the future, it is necessary to study the adjustment of LIB modules to be fed during roasting and the setting of collection areas and dismantling sites . 5.2 Future business plans As for the future schedule, the construction of a mass treatment system is to be started in 2019, input emissions labour-saving, business facilities permits and licences are to be obtained, and commercialisation is planned to start in 2021. 2016 2017 2018 2019 Relocation and modification of cement plant 2020 2021 2022-. 2025-. 2030-. Capacity expansio n works LIB Issue Measures Obtaining permits and licences c(eo.gm. Fimre Seerrcviicae,liza Waste Disposal and tPAiucotb,nlGicrCealetaFnirseing Prevention Act) relocate Safety measure s, etc. rapid cooling device Basket improvement Input and discharg e labour saving autom ated opera tion mass processing adaptation (e.g. expansion of storage space) Building multi- operati product onal knowhow processing investigati on (study) Establishment of a mass processin g system Check licensing proofcaedures Obtaining permits and apprroevspaolsnsfoer business facilities 500 t/year Figure 5-1. Schedule for the future 2,000t/year base) business expansion (New base established) 9,000 t/year (new 54 6. generalise In order to recycle used large LIB packs in a low-carbon treatment scheme, this demonstration project continued from the previous year to conduct demonstration experiments to recover high-grade metal resources from large LIB packs and modules using a roasting furnace. The treatment targets were a wide variety of large LIB packs and modules for automotive and stationary applications. Last year, the number of LIB pack types used in the demonstration experiment was small, so this year the number of types used was increased and the roasting conditions were verified under conditions close to those in actual operation. In addition, as a solution to the issues of the previous year, in order to examine roasting conditions that enable more efficient recovery of lithium compounds, we set the roasting temperature and time more precisely than in the previous year, verified the amount of paraffin used depending on the input amount and whether or not residual electricity is used, and conducted mass processing in continuous operation towards practical application, and identified and organised improvement issues. The implementation details and main results of this demonstration project are described below. The used large LIB packs and modules used in the verification experiment were LIB packs for vehicles from domestic and foreign automobile manufacturers and LIB modules for stationary use from domestic battery manufacturers . (i ) Separation and manual dismantling of used LIBs For the purpose of reducing the amount of roasting treatment and recovering base metal and plastic resources , used LIB packs were collected, sorted and dismantled by hand, and the amount of recovered resources was measured. Manual dismantling was only carried out for vehicle-mounted LIBs which were discharged in packs, but not for stationary LIBs which were discharged in modules. As a result of manual dismantling , the LIB packs used in this year had a higher ratio of module to pack weight than those used in the previous year , and each LIB pack had a different composition ratio of iron, non-ferrous and plastic . Roasting of spent LIBs Comparative verification of the roasting temperature range and heating time showed that the 500 C - 4 h combination had the highest base metal and rare metal recovery rate, the best lithium distribution rate to recovered material of less than 1 mm, and the lowest paraffin consumption per unit. A comparison of paraffin use by input volume confirms that the higher the input volume, the lower the paraffin use per input volume. Regarding the effect of residual power on roasting , a comparison of paraffin consumption by LIB module discharge with and without discharge showed that paraffin consumption per unit was lower in the case without discharge. This could be due to the 55 contribution of residual power as fuel. In the case where a large number of various LIB modules were mixed and roasted in continuous operation, the base metal was recovered at high efficiency as targeted, but the rare metal recovery rate was about 50 %, the same level as last year . Compared to the case where multiple LIB modules were roasted individually, the recovery rate varied, and knowledge was obtained that the recovery rate of rare metal differs depending on the LIB module. The lithium behaviour including the exhaust gas was also confirmed, and it was confirmed that lithium was not distributed in the exhaust gas at any input level. (iii) Crushing and sorting of roasted LIBs Highly efficient recovery of base metal and pole powder (<1 mm) containing lithium and other elements from roasted materials. 56 The recovered recovered materials were analysed to check the metal resource material balance in the LIB module. The recovered electrode powder of less than 1 mm and the recovered material of more than 1 mm were analysed for metal and the metal resource material balance in the LIB module was confirmed, and more than 80% lithium could be recovered in the electrode powder depending on the input level. (iv) Overall design of the treatment scheme. Based on the results of the demonstration experiment, the overall design of the used LIB pack recycling treatment was carried out and the recycling flow material balance was calculated. Used LIB packs As a processing flow, the LIBs in a pack state are dismantled manually, the base metal and plastic are recovered, and after being made into modules, they are roasted. The roasted materials are crushed by a shearing method, sieved, sorted and collected less than 1 mm electrode powder is recycled as lithium and other rare metals, and the materials collected more than 1 mm are recycled as copper. The scale of the treatment scheme was calculated to be based on a roasting treatment volume of 3,000 t/year (10 t/day), with approximately 4,600 t/year of used LIB packs to be treated, 744 t/year of polar powder and a total of 3,140 t/year of base metal resources to be recovered. As for energy saving effects, last year design As per last year's design, the use of exhaust heat from the cement firing process roasting furnace is expected to reduce annual kerosene consumption by about 30%, and the use of combustible exhaust gas generated from the roasting furnace for the cement firing furnace will reduce coal needed for cement production by about 0.1%. Replacement is expected. Environmental improvement effects In calculating the carbon dioxide reduction effect of the project scheme, the incineration process in a stationary furnace was set as the technology to be compared. Since it was difficult to obtain data on energy consumption in the treatment process before and after incineration in a stationary furnace, the hydrogen fluoride treatment process was excluded from the scope of calculation, assuming it to be the same as in the Project as a more conservative calculation. The recycling effect was included in the calculation only for the amount of resources that is actually assessed. The results of the estimation showed that the carbon dioxide reduction effect of processing a wide variety of LIB packs in a mixed manner was 434 kg-CO2/LIB pack. From the results of this year's demonstration, it is expected that the amount of kerosene used can be reduced less than in the previous year, resulting in a greater reduction effect. In the case of an annual roasting volume of 3,000 t/year processing scale, the carbon dioxide reduction effect was calculated to be 1,986 t-CO2/year . The actual assessed resource effect of resource recycling was calculated to be between 30% and 40%. The decrease from the previous year is thought to be due to the 57 different amounts of ferrous and non-ferrous that make up the LIB packs. It became clear that the resource recovery rate of LIB packs depends on the content of the materials that make up the LIB packs, but since the recovered materials that are not evaluated as metal are recycled by cement recycling, the amount of landfill disposal for any LIB packs i s 0, and therefore the recycling rate in this recycling system is 100%. Exhaust gas (containing hydrogen fluoride) As a result of verifying the behaviour of the halogen element (fluorine) contained in LIB packs, more than 80% of all LIB packs were distributed to polar powder of less than 1 mm. The rest was distributed in the roasting exhaust gas, which is sent to a cement kiln for detoxification. Measurements of the final exhaust gas from the cement production facility confirmed the fluorine detoxification process. 58 economic assessment The LIB pack treatment economics of the LIB pack treatment in this project was comprehensively evaluated by calculating the recovered resources valuables evaluation and the costs for transportation and treatment facilities, labour costs, consumables costs, etc. Among the recovered resources rare metal valuables were evaluated based on the concentration of the recovered materials. 1 mm or more recovered materials were all evaluated as copper. As a result of the estimation, the cost of each LIB pack was higher than the resource assessment, and the overall assessment was calculated to be around -JPY 150,000/t. The reason for the cost increase compared to last year can be attributed to the different material composition ratio of the LIB packs. The reason for the cost increase over the previous year can be attributed to the different material composition of the LIB packs . The material composition ratio of LIB packs differs depending on the material, and the cost of LIB modules increased. We would like to reflect this in the cost setting in actual operation. The results of this year's demonstration showed that the amount of paraffin used could be reduced by . It was calculated that this would result in a cost reduction of 2,000/t . We would like to continue to examine measures to reduce equipment and consumables costs for better economic evaluation. In order to reduce costs , we considered cost reduction through more efficient transport and mass processing, and we decided to set up a system in which roasting, crushing and sorting are carried out in one place, and the processing volume was tripled to 30t/day scale, which received an overall evaluation. The cost is expected to be reduced to around 100,000/t. As transport costs account for more than 1/3 of the total cost , it is necessary to consider the selection of demolition sites as well as the consolidation and scaling up of treatment facilities in the future. Future challenges and commercialisation timelines LIB packs have a wide variety of structures and material compositions. As a result of dismantling and roasting a wide variety of LIB packs in this project, it became clear that the resource recovery rate and the cost of treatment differ greatly depending on the material composition ratio of each LIB pack. These findings will be utilised in actual operation, for example by adjusting roasting conditions to increase the resource recovery rate. In addition, it is necessary to improve the packing, handling equipment and basket structure used in each process, such as collection, manual dismantling, roasting, crushing and sorting, in order to make the work more efficient and labour-saving when putting the material into practical use. As for the future schedule, the establishment of a mass treatment system will be promoted from 2019, input emissions labour-saving, demonstration facilities permits and approvals will be obtained, and commercialisation is planned from 2021. 59 2008 Technology demonstration project for CO2-saving recycling and other equipment. Automotive and other used lithium-ion batteries lowcarbon recycling system demonstration project Report 28 February 2019 Taiheiyo Cement Corporation Environmental Division tel: 03-5531-7417 60