Zhi Sun

Spent lithium-ion battery recycling - Reductive ammonia leaching of metals from cathode scrap by sodium sulphite.

Recycling of spent lithium-ion batteries has attracted wide attention because of their high content of valuable and hazardous metals. One of the difficulties for effective metal recovery is the separation of different metals from the solution after leaching. In this research, a full hydrometallurgical process is developed to selectively recover valuable metals (Ni, Co and Li) from cathode scrap of spent lithium ion batteries. By introducing ammonia-ammonium sulphate as the leaching solution and sodium sulphite as the reductant, the total selectivity of Ni, Co and Li in the first-step leaching solution is more than 98.6% while it for Mn is only 1.36%. In detail understanding of the selective leaching process is carried out by investigating the effects of parameters such as leaching reagent composition, leaching time (0-480min), agitation speed (200-700rpm), pulp density (10-50g/L) and temperature (323-353K). It was found that Mn is primarily reduced from Mn4+ into Mn2+ into the solution as [Formula: see text] while it subsequently precipitates out into the residue in the form of (NH4)2Mn(SO3)2·H2O. Ni, Co and Li are leached and remain in the solution either as metallic ion or amine complexes. The optimised leaching conditions can be further obtained and the leaching kinetics is found to be chemical reaction control under current leaching conditions. As a result, this research is potentially beneficial for further optimisation of the spent lithium ion battery recycling process after incorporating with metal extraction from the leaching solution.

Lithium Carbonate Recovery from Cathode Scrap of Spent Lithium-Ion Battery: A Closed-Loop Process

A closed-loop process to recover lithium carbonate from cathode scrap of lithium-ion battery (LIB) is developed. Lithium could be selectively leached into solution using formic acid while aluminum remained as the metallic form, and most of the other metals from the cathode scrap could be precipitated out. This phenomenon clearly demonstrates that formic acid can be used for lithium recovery from cathode scrap, as both leaching and separation reagent. By investigating the effects of different parameters including temperature, formic acid concentration, H2O2 amount, and solid to liquid ratio, the leaching rate of Li can reach 99.93% with minor Al loss into the solution. Subsequently, the leaching kinetics was evaluated and the controlling step as well as the apparent activation energy could be determined. After further separation of the remaining Ni, Co, and Mn from the leachate, Li2CO3 with the purity of 99.90% could be obtained. The final solution after lithium carbonate extraction can be further processed for sodium formate preparation, and Ni, Co, and Mn precipitates are ready for precursor preparation for cathode materials. As a result, the global recovery rates of Al, Li, Ni, Co, and Mn in this process were found to be 95.46%, 98.22%, 99.96%, 99.96%, and 99.95% respectively, achieving effective resources recycling from cathode scrap of spent LIB.

A Cleaner Process for Selective Recovery of Valuable Metals from Electronic Waste of Complex Mixtures of End-of-Life Electronic Products

In recent years, recovery of metals from electronic waste within the European Union has become increasingly important due to potential supply risk of strategic raw material and environmental concerns. Electronic waste, especially a mixture of end-of-life electronic products from a variety of sources, is of inherently high complexity in composition, phase, and physiochemical properties. In this research, a closed-loop hydrometallurgical process was developed to recover valuable metals, i.e., copper and precious metals, from an industrially processed information and communication technology waste. A two-stage leaching design of this process was adopted in order to selectively extract copper and enrich precious metals. It was found that the recovery efficiency and extraction selectivity of copper both reached more than 95% by using ammonia-based leaching solutions. A new electrodeposition process has been proven feasible with 90% current efficiency during copper recovery, and the copper purity can reach 99.8 wt %. The residue from the first-stage leaching was screened into coarse and fine fractions. The coarse fraction was returned to be releached for further copper recovery. The fine fraction was treated in the second-stage leaching using sulfuric acid to further concentrate precious metals, which could achieve a 100% increase in their concentrations in the residue with negligible loss into the leaching solution. By a combination of different leaching steps and proper physical separation of light materials, this process can achieve closed-loop recycling of the waste with significant efficiency.

Characterisation of metals in the electronic waste of complex mixtures of end-of-life ICT products for development of cleaner recovery technology

Recycling of valuable metals from electronic waste, especially complex mixtures of end-of-life information and communication technology (ICT) products, is of great difficulty due to their complexity and heterogeneity. One of the important reasons is the lack of comprehensive characterisation on such materials, i.e. accurate compositions, physical/chemical properties. In the present research, we focus on developing methodologies for the characterisation of metals in an industrially processed ICT waste. The morphology, particle size distribution, compositional distribution, occurrence, liberation as well as the thermo-chemical properties of the ICT waste were investigated with various characterisation techniques, including X-ray Fluorescence Spectrometry (XRF), differential scanning calorimetry (DSC) and scanning electron microscopy (SEM) with energy dispersed spectroscopy (EDS). Due to the high heterogeneity of the material, special sample preparation procedures were introduced to minimise the discrepancies during compositional analyses. As a result, a clearer overview of the ICT waste has been reached. This research provides better understanding of the extractability of each metal and improves the awareness of potential obstacles for extraction. It will lead to smarter decisions during further development of a clean and effective recovery process.

Spent lead-acid battery recycling in China – A review and sustainable analyses on mass flow of lead

Lead is classified to be one of the top heavy metal pollutants in China. The corresponding environmental issues especially during the management of spent lead-acid battery have already caused significant public awareness and concern. This research gives a brief overview on the recycling situation based on an investigation of the lead industry in China and also the development of technologies for spent lead-acid batteries. The main principles and research focuses of different technologies including pyrometallurgy, hydrometallurgy and greener technologies are summarized and compared. Subsequently, the circulability of lead based on the entire life cycle analyses of lead-acid battery is calculated. By considering different recycling schemes, the recycling situation of spent lead-acid battery in China can be understood semi-quantitatively. According to this research, 30% of the primary lead production can be shut down that the lead production can still ensure consecutive life cycle operation of lead-acid battery, if proper management of the spent lead-acid battery is implemented according to current lead industry situation in China. This research provides a methodology on the view of lead circulability in the whole life cycle of a specific product and is aiming to contribute more quantitative guidelines for efficient organization of lead industry in China.

Induced migration of non-magnetic particles and fabrication of metallic-based graded materials by applying a strong magnetic field

Strong magnetic fields e.g., 10 T are now frequently used during materials preparation. In the present paper, a method of metal-ceramics graded materials preparation is proposed by applying a strong magnetic field with a high gradient. Experimental and theoretical analyses are performed to investigate the effect of the strong magnetic field on the migration and interaction behavior of diamagnetic oxide particles in a liquid metal. The migration of micrometer or sub-micrometer sized particles is clearly enhanced by the magnetic field gradient. After being treated by the strong magnetic field, a self-assembly structure of the particles is achieved. Various factors such as the magnetic dipole-dipole interaction and chain-chain interaction, are governing the particles assembly. The present results provide direct evidence that nonmetallic particles of micrometer size or less can be manipulated in a conductive melt by applying a strong magnetic field and as a consequence graded materials can be prepared.

Thermodynamics Study on the Decomposition of Chromite with KOH

Institute of Process Engineering, Chinese Academy of Sciences, China, has proposed a method for oxidative leaching of chromite with potassium hydroxide. Understanding the mechanism of chromite decomposition, especially in the potassium hydroxide fusion, is important for the optimization of the operating parameters of the oxidative leaching process. A traditional thermodynamic method is proposed and the thermal decomposition and the reaction decomposition during the oxidative leaching of chromite with KOH and oxygen is discussed, which suggests that chromite is mainly destroyed by reactions with KOH and oxygen. Meanwhile, equilibrium of the main reactions of the above process was calculated at different temperatures and oxygen partial pressures. The stable zones of productions, namely, K 2 CrO 4 and Fe 2 O 3 , increase with the decrease of temperature, which indicates that higher temperature is not beneficial to thermodynamic reactions. In addition, a comparison of the general alkali methods is carried out, and it is concluded that the KOH leaching process is thermodynamically superior to the conventional chromate production process.

Complex electronic waste treatment - An effective process to selectively recover copper with solutions containing different ammonium salts.

Recovery of valuable metals from electronic waste has been highlighted by the EU directives. The difficulties for recycling are induced by the high complexity of such waste. In this research, copper could be selectively recovered using an ammonia-based process, from industrially processed information and communication technology (ICT) waste with high complexity. A detailed understanding on the role of ammonium salt was focused during both stages of leaching copper into a solution and the subsequent step for copper recovery from the solution. By comparing the reactivity of the leaching solution with different ammonium salts, their physiochemical behaviour as well as the leaching efficiency could be identified. The copper recovery rate could reach 95% with ammonium carbonate as the leaching salt. In the stage of copper recovery from the solution, electrodeposition was introduced without an additional solvent extraction step and the electrochemical behaviour of the solution was figured out. With a careful control of the electrodeposition conditions, the current efficiency could be improved to be 80-90% depending on the ammonia salts and high purity copper (99.9wt.%). This research provides basis for improving the recyclability and efficiency of copper recovery from such electronic waste and the whole process design for copper recycling.

Effect of the strong magnetic field on the magnetic interaction between two non-magnetic particles migrating in a conductive fluid

This paper presents a theoretical analysis of the interaction between two non-magnetic particles migrating in a conductive fluid due to an imposed strong magnetic field. A repulsive force induced by the conductive fluid flow around the particles is first derived and calculated for a concrete example. From the numerical results, a counteracting behavior with the interparticle magnetic dipole-dipole attractive force is found to exist at a critical particle size which makes the particles controllable under strong magnetic fields (e.g., B> 10 T). This renders a better understanding of recent experimental results and provides a basis to control the particle size distribution using strong magnetic fields for materials processing. Copyright c EPLA, 2009

Alkaline electrochemical advanced oxidation process for chromium oxidation at graphitized multi-walled carbon nanotubes

Alkaline electrochemical advanced oxidation processes for chromium oxidation and Cr-contaminated waste disposal were reported in this study. The highly graphitized multi-walled carbon nanotubes g-MWCNTs modified electrode was prepared for the in-situ electrochemical generation of HO2-. RRDE test results illustrated that g-MWCNTs exhibited much higher two-electron oxygen reduction activity than other nanocarbon materials with peak current density of 1.24xa0mAxa0cm-2, %HO2- of 77.0% and onset potential ofxa0-0.15xa0V (vs. Hg/HgO). It was originated from the highly graphitized structure and good electrical conductivity as illustrated from the Raman, XRD and EIS characterizations, respectively. Large amount of reactive oxygen species (HO2- and ·OH) were in-situ electro-generated from the two-electron oxygen reduction and chromium-induced alkaline electro-Fenton-like reaction. The oxidation of Cr(III) was efficiently achieved within 90xa0min and the conversion ratio maintained more than 95% of the original value after stability test, offering an efficient and green approach for the utilization of Cr-containing wastes.