Sustainable method for disposing of ceramic-coated battery separator via carbon dioxide-assisted thermochemical process

Abstract

The increasing demand for energy storage systems is driven by variability in renewable energy sources and the substantial energy requirements of electric vehicles. However, the typical 3–10-year lifespan of lithium-ion batteries raises concern about their disposal. The environmental challenges associated with conventional disposal and recycling methods (landfilling, incineration, and pyrometallurgical/hydrometallurgical processes) include the release of microplastics and air pollutants, such as volatile organic compounds, from plastic components. To address these issues, we propose a thermochemical process for managing plastic waste from discarded batteries, focusing on a separator from lithium-ion batteries as a model feedstock. Using carbon dioxide (CO2) as a reaction medium enhances the sustainability of thermochemical processes. Specifically, co-feeding CO2 at elevated temperatures (≥500°C) improves syngas and C1–2-hydrocarbon production while reducing liquid pyrolysates. These reactions result from the partial oxidation of volatiles via gas-phase reactions with CO2. Incorporation of CO2 to optimize the conversion of battery separators into syngas represents an advancement toward the environmentally sound and efficient disposal of battery waste while yielding value-added products.