Classifications

• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01D—COMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
  • C01D15/00—Lithium compounds
  • C01D15/005—Lithium hexafluorophosphate
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/056—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
  • H01M10/0564—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of organic materials only
  • H01M10/0566—Liquid materials
  • H01M10/0568—Liquid materials characterised by the solutes
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M6/00—Primary cells; Manufacture thereof
  • H01M6/14—Cells with non-aqueous electrolyte
  • H01M6/16—Cells with non-aqueous electrolyte with organic electrolyte
  • H01M6/162—Cells with non-aqueous electrolyte with organic electrolyte characterised by the electrolyte
  • H01M6/166—Cells with non-aqueous electrolyte with organic electrolyte characterised by the electrolyte by the solute
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries

Definitions

• THIS INVENTION relates to the production of lithium hexafluorophosphate.
• the invention provides a method of producing lithium hexafluorophosphate and extends to lithium hexafluorophosphate produced in accordance with the method.
• the invention also extends to a method of producing an electrolyte and extends to an electrolyte produced in accordance with the method.
• the invention also provides an electric battery and a method of manufacturing an electric battery.
• LiPFe lithium hexafluorophosphate
• LiPF6 Conventional preparation methods of LiPF6 include wet chemical synthesis methods in aqueous reaction conditions and dry synthesis methods in non-aqueous conditions.
• a common method of preparing LiPF6 using a wet chemical preparation method involves synthesizing water stable organic complexes such as pyridinium or tetraacetonitrilolithium hexafluorophosphate, and converting the complexes into solvated LiPF6.
• the pyridinium cation is preferred to the acetonitrile cation as the latter poorly dissolves the lithium base used in a subsequent reaction to substitute the organic cation.
• tetraacetonitrilolithium hexafluorophosphate complex produced by a reaction of LiF salt and PFs gas in the presence of acetonitrile allows low temperature decomposition of the complex in vacuum (20 °C) to produce high purity LiPF6.
• Z is oxygen or sulphur
• X is chlorine or bromine.
• hexafluorophosphate complexes of ammonia and alkali metals can be prepared by reacting ammonium or alkali metal fluorides with phosphorus pentachloride, however, the subsequent isolation process is tedious and time consuming as the yields are very low.
• Another preparation method of LiPF6 using wet chemical synthesis involves reacting hexafluorophosphoric acid with pyridine to form the complex, and then exchanging the pyridinium cation with a lithium cation from a hydroxide or alkoxide to obtain a LiPF6 pyridine complex which can be treated further to produce high purity LiPF6. This is illustrated in Equations 1 .3 and 1 .4:
• the lithium base used in this method is dissolved in an alcohol media to avoid a subsequent reaction between the synthesized LiPF6 and water.
• This method is based on the fact that alkali metal ions from corresponding hydroxides are easily exchanged with the pyridinium cation.
• the pyridinium hexafluorophosphate yield is approximately 70%, and a further 96% LiPF6 crystalline product is obtained from a subsequent reaction of the complex with a lithium base and drying the product in a partial vacuum at 30 °C.
• Flexafluorophosphoric acid may also be reacted with lithium hydroxide in water to form LiPF6, however, the formed electrolyte quickly hydrolyzes and precipitate in the form of various other species such as PO2F2 , PO4 3 , and HPO3F ⁇ .
• Another disadvantage associated with this preparation method includes the use of hexafluorophosphoric acid which is a mixture of several weak acids resulting from gradual decomposition of the HPF6 itself. Therefore, the amount of PF6 ion available to react is not always known. This requires that a preliminary titration be undertaken between the acid and an alkali hydroxide to determine the exact stoichiometry of the PF6 ion in the acid before neutralization with pyridine.
• an ether with at least two functionalities and enough spacing to complex a lithium ligand, for example, 1 ,2-dimethoxyethane is used to dissolve the ammonium hexafluorophosphate salt.
• the complex 2DME.UPF6, ammonia and hydrogen gas are formed as products.
• the complex is stable and is further dissolved in an electrolyte solvent for applications in batteries, however, the ether is difficult to remove and will feature in the final electrolyte.
• the reaction between a lithium source, for example LiH, and NFLPF6 can be carried out directly in a solvent to be used in the final electrolyte. At least one of the reactants must be soluble and the other should be insoluble in the solvent used so that excess salts can be easily removed via precipitation from the electrolyte. If a two solvent process is carried out, then the initial solvent used must be non-protic, have high solubility for the lithium compound used and possess a low boiling point. A more viscous, high boiling point solvent, such as ethylene carbonate (EC), can then be added as a co-solvent followed by the evaporation of the initial solvent.
• EC ethylene carbonate
• Lithium hexafluorophosphate may also be synthesized using LiF and PCIs in water, however, low yields are obtained with this preparation method.
• a chloride salt such as LiCI or even LiF is dissolved in anhydrous HF, and then PCIs is slowly added to precipitate a lithium hexafluorophosphate salt with a higher yield.
• a further method of preparing L1PF6 involves using PCh and HF in an anhydrous organic solvent of the type carbonic ethers and esters.
• the carbonates such as ethyl carbonate and other related solvents react and form adducts with PFs gas. Not only is the reaction of PFs and the solvent a challenge when this preparation method is used, but the introduction of HF is not desirable as it will further react and introduce additional complications.
• LiPF6 salt itself is thermally unstable and will decompose during thermal treatment to remove the solvent used.
• a widely used method for the synthesis of LiPF6 using non-aqueous conditions involves a reaction between LiF and PFs gas to form LiPF6.
• Various drawbacks are associated with this method, including the difficulty of handling poisonous PFs gas and low product purity (90-95%) compared to the required purity of at least 99.9% of UPF6 used in battery applications.
• Excess LiF and UFIF2 are also formed as by-products in this preparation method.
• This technique has been modified to improve the purity of the UPF6 product by reacting acetonitrile with the obtained UPF6 to form tetraacetonitrilolithium hexafluorophosphate, which, upon partial heating in vacuum, regenerates a purer UPF6 salt.
• the UPF6 salt may also be synthesized by reacting lithium fluoride and bromine trifluoride in excess phosphorous pentoxide.
• Other methods for UPF6 synthesis involve in situ generation of PFs gas and its subsequent reaction with a lithium source to form the UPF6 salt. This technique is said to eliminate moisture ingress into the intermediates during the chemical reaction.
• Solid state thermal reactions provide alternative dry synthesis methods to the gaseous routes for the preparation of L1PF6.
• a lithium source for an example, may be reacted with a phosphate such as ammonium phosphate at a high temperature (300 °C) in a solid state to form lithium metaphosphate, which is then further reacted with ammonium fluoride at 150 °C to obtain LiPF6.
• a phosphate such as ammonium phosphate at a high temperature (300 °C) in a solid state to form lithium metaphosphate, which is then further reacted with ammonium fluoride at 150 °C to obtain LiPF6.
• Equations 1 .6 and 1 .7 Solid state thermal reactions tend to be incomplete if powders are mixed as received and heated at elevated temperatures. This, therefore, presents a challenge to thoroughly grind the reactants together and press them into pellets to facilitate contact between them.
• LiPF6 can be produced by reacting phosphorus with fluorine gas at a temperature of 23°C to generate PFs gas, which, is then reacted in situ with LiF to produce LiPF6.
• the fluorine gas is first liquefied at -196 °C using liquid nitrogen, and then the temperature is increased stepwise to -80 °C, where the reaction commenced.
• the reaction is allowed to occur slowly until a temperature of 23 °C where the LiPF6 production rate is high.
• the temperature is further elevated to 150 °C to obtain a purer product.
• This technique is time consuming, and the reaction is expected to be completed after 10 hr, which is expensive in terms of production time. It is an object of the invention to at least alleviate the drawbacks mentioned above, and particularly to minimize and more preferably to avoid completely the formation of HF.
• LiPFe lithium hexafluorophosphate
• the method including reacting lithium fluoride (LiF) with phosphorous pentafluoride (PFs) in a liquid medium that comprises a perhalogenated organic compound that is non-reactive with, i.e. is inert to, the PFs and is a solvent for the PFs, thereby producing LiPF6 in solid, e.g. granular, form.
• the reaction is therefore performed in the liquid medium.
• the LiPF6 is produced in the liquid medium in solid form. It follows that the liquid medium is not a solvent for LiPF6 in solid form.
• the liquid medium may be provided by the perhalogenated organic compound, with the perhalogenated organic compound thus being a liquid perhalogenated organic compound.
• the liquid medium would therefore consist of the perhalogenated organic compound.
• perhalogenated organic compound may be employed as or comprised by the liquid medium. Such mixtures are included within the scope of the invention, and in a broad sense the term perhalogenated organic compound therefore includes mixtures of two or more perhalogenated organic compounds.
• the halogen of the perhalogenated organic compound may, in particular, be fluorine.
• perhalogenated means, as is conventionally understood in the art of the invention, a fully halogenated version of an organic compound, in that all of the hydrogen atoms of the organic compound have been substituted with halogen atoms, thus providing the perhalogenated organic compound.
• organic compound decalin C-I OH-I S
• perhalogenated organic compound is perfluorodecalin (C-ioF-ie).
• the perhalogenated organic compound may be a virtually fully halogenated version of the organic compound, in which case the perhalogenated organic compound may still include some hydrogen atoms;
• the perhalogenated organic compound is not a saturated organic compound, e.g. that it is an alkene or an alkyne,
• the extent of halogenation of the organic compound, as embodied in the perhalogenated organic compound is such that the perhalogenated organic compound is inert to the PFs, i.e. is non-reactive with the PFs, and is a solvent for the PFs.
• the LiF may be in solid, e.g. granular, form.
• the liquid medium would not be a solvent for LiF in solid form.
• the PFs may be gaseous PFs.
• Reacting the LiF with gaseous PFs may therefore include
• reacting the LiF in solid form with gaseous PFs therefore does not necessarily include directly contacting the LiF in solid form with gaseous PFs. Instead, reacting the LiF in solid form with gaseous PFs would include contacting the liquid medium that contains the LiF in solid form with gaseous PFs.
• the perhalogenated organic compound is inert to the PFs.
• the perhalogenated organic compound is non-reactive with the PFs in the sense that the PFs does not chemically react with the perhalogenated organic compound to form a new compound.
• the perhalogenated organic compound may be a perhalogenated alkane.
• the perhalogenated alkane may be a cyclic or non-cyclic perfluorocarbon, preferably of the formula CxF y where x is an integer selected from 1 to 10 and y is an integer selected from 4 to 20, such as perfluorodecalin or perfluoroheptane or a non-cyclic perfluorocarbon selected from CI F 4 and C6FI 4 to C9F20.
• the perhalogenated organic compound may be a perfluoroalkene.
• the perfluoroalkene may be a perfluoroaromatic compound such as hexafluorobenzene or a perfluoroaromatic compound selected from C6F6 to C-ioFs, or tetrafluoroethylene or a perfluoroalkene selected from C3F6 or C4F8.
• the perhalogenated organic compound may further be an ether, and particularly a perfluoroalkene ether.
• a typical generic formula may be R-O-R’.
• the perhalogenated organic compound may in one embodiment be a perfluorocarbon.
• the perfluorocarbon may be selected from cyclic and non-cyclic perfluoroalkanes, and cyclic and non-cyclic perfluoroalkenes, and mixtures of any two or more thereof, severally or jointly.
• the perfluorocarbon may be selected from perfluorodecalin, perfluoroheptane, hexafluorobenzene, tetrafluoroethylene, and mixtures of any two or more thereof.
• the produced LiPF6 would also be in solid form.
• the reaction between the LiF and the PFs would convert the LiF in solid form into LiPF6 in solid form.
• the method may in some cases produce a mixture of LiPF6 in solid form and unreacted LiF in solid form, contained in the liquid medium.
• the method may include recovering LiPF6 in solid form and any unreacted LiF in solid form from the liquid medium, e.g. by physical separation such as by filtration.
• the method may include dissolving the LiPF6 in solid form in a solvent for LiPF6, thus producing a solution of LiPF6.
• Producing the solution of LiPF6 may be particularly, but not exclusively, applicable when the method produces the mixture of LiPF6 in solid form and unreacted LiF in solid form as hereinbefore described, to recover LiPF6 from the mixture of LiPF6 in solid form and unreacted LiF in solid form.
• the method may include treating the mixture of LiPF6 in solid form and unreacted LiF in solid form with a solvent for LiPF6 in solid form.
• the solvent for LiPF6 in solid form would not be a solvent for LiF in solid form.
• the solvent for LiPF6 in solid form may be an electrolyte solvent, suitable for use in an electric battery, particularly a lithium-ion battery.
• the solvent may be selected from ethylene carbonate, propylene carbonate, dimethyl carbonate, dimethyl ether, and mixtures thereof.
• the method is preferably effected in the absence of other reactants, e.g. hydrochloric acid.
• the reaction may be carried out at a pressure in a range of from 0 kPa to 3 000 kPa.
• the temperature at which the reaction would be carried out would be such that the stated phase conditions of the various components would prevail for the purpose of the reaction.
• the solvent for LiPF6 in solid form may be an electrolyte solvent, suitable for use in an electric battery.
• the solvent may be selected from ethylene carbonate, propylene carbonate, dimethyl carbonate, dimethyl ether, and mixtures thereof.
• the electrolyte may be an electrolyte for an electric battery, particularly a lithium-ion battery.
• the electrolyte may be an electrolyte produced in accordance with the method of the third aspect of the invention.
• the electric battery may be a lithium-ion battery.
• the electric battery may be a lithium-ion battery
• Example 1 Reaction between LiF and PF5 gas in the presence of a cyclic or polycyclic perfluorocarbon solvent
• a clean, thick-walled stainless-steel reactor capable of handling more than 10 bar of gas pressure was loaded with 2g of LiF solid powder purchased from Sigma-Aldrich or Alpha-Aesar.
• the reactor was then sealed in a glovebox and connected to a system consisting of a vacuum line, a high-pressure indicator and a high-pressure PFs gas cylinder. PFs gas was introduced from its feed cylinder into the reactor, thus contacting the suspension of LiF in perfluorodecalin.
• the reaction was allowed to digest for at least 1 day.
• the reactor was then transferred to a nitrogen glove box for opening in a dry, inert environment.
• the retentate was dried using nitrogen in a glovebox and a mixture of unreacted LiF and formed LiPF6, which was previously in suspension in the liquid medium, was recovered in solid form.
• reaction equation 1 The reaction that took place is in accordance with reaction equation 1 :
• LiPF6 LiF(s) + PFs (g) LiPFe (s) (Eq. 1 ) LiPF6 was recovered from the mixture of LiPF6 and unreacted LiF using a solvent for LiPF6. Conversion of LiF in excess of 90% have been observed, with LiPF6 recovery of up to 99%.
• Suitable solvents include ethylene carbonate, propylene carbonate, dimethyl carbonate, dimethyl ether, or combinations thereof.
• Example 2 A reaction between LiF and PF5 gas in the presence of non-cyclic or branched perfluorocarbon solvent
• LiF in solid form is dispersed in liquid perfluoroheptane or any non-cyclic perfluorocarbons of range CI F 4 , and C6FI 4 to C9F20 liquid.
• reaction equation 1 The reaction that takes place is in accordance with reaction equation 1 .
• the reaction temperature range is -94 °C to 127 °C.
• the reaction pressure range is 0 kPa to 3 000 kPa, more preferably up to 1000 kPa.
• LiPF6 Up to 99% recovery of LiPF6 may be achieved when produced LiPF6 is dissolved in a solvent for LiPF6 in solid form, which solvent comprises ethylene carbonate, propylene carbonate, dimethyl carbonate, dimethyl ether, or any combination thereof.
• Example 3 A reaction between LiF and PF 5 gas in the presence of perfluoroaromatic solvent LiF in solid form is dispersed in liquid hexafluorobenzene or a perfluoroaromatic liquid compound in the range C6F6 to C-ioFs.
• reaction equation 1 The reaction that takes place is in accordance with reaction equation 1 .
• the reaction temperature range is 5°C to 100 °C.
• the reaction pressure range is 0 kPa to 3 000 kPa, more preferably up to 1000 kPa.
• LiPF6 Up to 99% recovery of LiPF6 may be achieved when produced LiPF6 is dissolved in a solvent for LiPF6 in solid form, which solvent comprises ethylene carbonate, propylene carbonate, dimethyl carbonate, dimethyl ether, or any combination thereof.
• Example 4 A reaction between LiF and PF 5 gas in the presence of fluoroalkene solvent.
• LiF in solid form is dispersed in liquid tetrafluoroethylene solvent (C2F 4 ) or a liquid fluoroalkene compound selected from C3F6 or C4F8.
• reaction equation 1 The reaction that takes place is in accordance with reaction equation 1 .
• the reaction temperature range is -94°C to 100 °C.
• the reaction pressure range is 0 kPa to 3 000 kPa, more preferably up to 1000 kPa. Up to 99% recovery of LiPF6 may be achieved when produced LiPF6 is dissolved in a solvent for LiPF6 in solid form, which solvent comprises ethylene carbonate, propylene carbonate, dimethyl carbonate, dimethyl ether, or any combination thereof.
• THE METHOD OF THE FIRST ASPECT OF THE INVENTION uses an inert, non- corrosive, non-poisonous liquid medium for the reaction of LiF and PFs instead of corrosive HF which is the preferred liquid medium for this reaction in the art of the invention.
• the inventors have eliminated the need to remove the HF from the product through tiresome purification processes such as vacuum distillation.
• HF is known to be corrosive and reactive inside a battery, which makes its avoidance for use as a liquid medium all the more desirable.
• liquid media are non-corrosive.

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