2025 AIChE Annual Meeting

(400as) Optimization of Energy Efficient Solvent Recovery in Battery Manufacturing Under Uncertainty

Authors

Taeho Mun - Presenter, Korea Institute of Energy Research
Sung-il Kim, Korea Institute of Energy Research
The surge in global demand for batteries has led to a corresponding increase in energy consumption, particularly in solvent recovery processes (SRPs) such as N-methyl-2-pyrrolidone (NMP) recovery systems. These processes are inherently energy intensive, primarily due to the complexity of separating high boiling point solvents. As a result, improving the efficiency of SRPs is emerging as a key priority to reduce both the operating costs and environmental footprint associated with battery manufacturing. However, SRPs are often affected by a number of uncertainties and external disturbances-chief among them are changes in feed flow rates, variations in solvent composition, and the pressures of expanding production capacity. Left unaddressed, these variables can significantly complicate system operation and design, often resulting in avoidable inefficiencies. To address these challenges, this study presents a comprehensive NMP recovery process model constructed in ASPEN Plus. The model rigorously integrates fundamental mass and energy balances along with accurate thermodynamic data. An accompanying optimization framework was used to derive design and operational strategies that not only ensure high recovery efficiencies, but also ensure economic viability. Importantly, the model accounts for fluctuating production conditions and process disturbances, providing robust, adaptive solutions tailored to real-world industrial environments. The results provide practical strategies for improving solvent recovery rates, reducing overall energy requirements, and promoting greater sustainability in battery production. This work provides actionable guidance for developing more efficient, resilient SRP systems that address both the economic and environmental challenges posed by the rapid growth of global battery production.