Electrochemical approaches for selective recovery of critical elements in hydrometallurgical processes of complex feedstocks

A review of greener approaches for rare earth elements recovery from mineral wastes

The use of rare earth elements (REE) in many various fields, including high-tech products, increases the demand for these materials day by day. The production of REE from primary sources has expanded in response to increasing demand; however, due to its limited, a more sustainable supply is also started to offer for the REE demand by using secondary sources. The most commonly used metallurgical method for REE recovery is hydrometallurgical processes. However, it has some disadvantages, like pyrometallurgical methods. In the review, studies of the environmental impacts of REE production from primary sources and life cycle assessments of products containing REE were investigated. According to the results, it has been seen that those studies in the literature in which hydrometallurgical methods have changed to more environmentally friendly approaches have begun to increase. In this review, mine wastes, which are secondary sources, were defined, conventional methods of recovery of rare earth elements were discussed, greener approaches to the recovery of REE from these sources were comprehensively examined and studies in the literature were evaluated. Furthermore, it was stated that there are limited studies on green approaches and REE recovery from mineral wastes and that this field is developing with an emphasis on the current outlook and future perspectives.

Unraveling the Role of Solvation and Ion Valency on Redox-Mediated Electrosorption through In Situ Neutron Reflectometry and Ab Initio Molecular Dynamics

Solvation and ion valency effects on selectivity of metal oxyanions at redox-polymer interfaces are explored through in situ spatial-temporally resolved neutron reflectometry combined with large scale ab initio molecular dynamics. The selectivity of ReO4- vs MoO42- for two redox-metallopolymers, poly(vinyl ferrocene) (PVFc) and poly(3-ferrocenylpropyl methacrylamide) (PFPMAm) is evaluated. PVFc has a higher Re/Mo separation factor compared to PFPMAm at 0.6 V vs Ag/AgCl. In situ techniques show that both PVFc and PFPMAm swell in the presence of ReO4- (having higher solvation with PFPMAm), but do not swell in contact with MoO42-. Ab initio molecular simulations suggest that MoO42- maintains a well-defined double solvation shell compared to ReO4-. The more loosely solvated anion (ReO4-) is preferably adsorbed by the more hydrophobic redox polymer (PVFc), and electrostatic cross-linking driven by divalent anionic interactions could impair film swelling. Thus, the in-depth understanding of selectivity mechanisms can accelerate the design of ion-selective redox-mediated separation systems for transition metal recovery and recycling.

Advances in bio/chemical approaches for sustainable recycling and recovery of rare earth elements from secondary resources

Rare Earth Elements (REEs) are indispensable in the growing smart technologies, such as smart phones and electronic devices, renewable energy, new generation of hybrid cars, etc. These elements are naturally occurring in specific geological deposits (bastnäsite, monazite, and xenotime), primarily concentrated in the regions of China, Australia, and the USA. The extraction and processing of REEs and the mismanagement of secondary REE resources, such as industrial waste, end-of-life materials, and mining by-products, raise major environmental and health concerns. Recycling represents a convincing solution, avoiding the necessity to separate low-value or coexisting radioactive elements when REEs are recovered from raw ore. Despite these advantages, only 1 % of REEs are usually recycled. This review overreached strategies for recycling REEs from secondary resources, emphasizing their pivotal role. The predominant approach for recycling REEs involves hydrometallurgical processing by leaching REEs from their origins using acidic solutions and then separating them from dissolved impurities using techniques like liquid-liquid extraction, membrane separation, chromatography, adsorption, flotation, and electrochemical methods. However, these methods have notable disadvantages, particularly their over requirements for water, reagents, and energy. Biohydrometallurgy introduces an innovative alternative using microorganisms and their metabolites to extract REEs through bioleaching. Other investigations are carried out to recover REEs through biological strategies, including biosorption, affinity chromatography with biological ligands, bioflotation employing biological surfactants, and bioelectrochemical methods. However, biohydrometallurgical processes can also be relatively slow and less suitable for large-scale applications, often lacking specificity for targeted REEs recovery. Overcoming these challenges necessitates ongoing research and development efforts to advance recycling technologies.

Driving sustainable circular economy in electronics: A comprehensive review on environmental life cycle assessment of e-waste recycling

E-waste, encompassing discarded materials from outdated electronic equipment, often ends up intermixed with municipal solid waste, leading to improper disposal through burial and incineration. This improper handling releases hazardous substances into water, soil, and air, posing significant risks to ecosystems and human health, ultimately entering the food chain and water supply. Formal e-waste recycling, guided by circular economy models and zero-discharge principles, offers potential solutions to this critical challenge. However, implementing a circular economy for e-waste management due to chemical and energy consumption may cause environmental impacts. Consequently, advanced sustainability assessment tools, such as Life Cycle Assessment (LCA), have been applied to investigate e-waste management strategies. While LCA is a standardized methodology, researchers have employed various routes for environmental assessment of different e-waste management methods. However, to the authors' knowledge, there lacks a comprehensive study focusing on LCA studies to discern the opportunities and limitations of this method in formal e-waste management strategies. Hence, this review aims to survey the existing literature on the LCA of e-waste management under a circular economy, shedding light on the current state of research, identifying research gaps, and proposing future research directions. It first explains various methods of managing e-waste in the circular economy. This review then evaluates and scrutinizes the LCA approach in implementing the circular bioeconomy for e-waste management. Finally, it proposes frameworks and procedures to enhance the applicability of the LCA method to future e-waste management research. The literature on the LCA of e-waste management reveals a wide variation in implementing LCA in formal e-waste management, resulting in diverse results and findings in this field. This paper underscores that LCA can pinpoint the environmental hotspots for various pathways of formal e-waste recycling, particularly focusing on metals. It can help address these concerns and achieve greater sustainability in e-waste recycling, especially in pyrometallurgical and hydrometallurgical pathways. The recovery of high-value metals is more environmentally justified compared to other metals. However, biometallurgical pathways remain limited in terms of environmental studies. Despite the potential for recycling e-waste into plastic or glass, there is a dearth of robust background in LCA studies within this sector. This review concludes that LCA can offer valuable insights for decision-making and policy processes on e-waste management, promoting environmentally sound e-waste recycling practices. However, the accuracy of LCA results in e-waste recycling, owing to data requirements, subjectivity, impact category weighting, and other factors, remains debatable, emphasizing the need for more uncertainty analysis in this field.

Electrochemical treatment of wastewaters containing metal-organic complexes: A one-step approach for efficient metal complex decomposition and selective metal recovery

Metal-organic complexes, especially those of ethylenediaminetetraacetic acid (EDTA) with metals such as copper (Cu) and nickel (Ni) (denoted here as Cu-EDTA and Ni-EDTA), are common contaminants in wastewaters from chemical and plating industries. In this study, a multi-electrode (ME) system using a two-chamber reactor and two pairs of electrodes is proposed for simultaneous electrochemical oxidation of a wastewater containing both Cu-EDTA and Ni-EDTA complexes as well as separation and selective recovery of Cu and Ni onto two different cathodes via electrodeposition. Our results demonstrate that the ME system successfully achieved 90% EDTA removal, 99% solid Cu recovery at the Cu recovery cathode and 56% Ni recovery (33.3% on the Ni recovery cathode and 22.6% in the solution) after a four-hour operation. The system further achieved 85.5% Ni recovery after consecutive five cycles of operation for 20 h. While Cu removal was mainly driven by the direct reduction of EDTA-complexed Cu(II) at the cathode, oxidation of EDTA within the Ni-EDTA complex at the anode was a prerequisite for Ni removal. The oxidation of metal-bound EDTA and free EDTA was driven by •OH and direct electron transfer on the PbO2 anode surface and graphite anode, respectively. We further show that ME system performs well for all pH conditions, treatment of real wastewaters as well as wastewaters containing other metals ions (Cr and Zn) along with Cu/Ni. The separation efficiency of Cu and Ni is dependent on applied electrode potential as well as nature and concentration of binding ligand present with comparatively lower separation efficiency achieved in the presence of weaker binding capacity and/or at lower ligand concentration and lower applied electrode potential. As such, some optimization of electrode potential is required depending on the nature/concentration of ligands in the wastewaters. Overall, this study provides new insights into the design and operation of EAOP technology for effective organic abatement and metal recovery from wastewaters containing mixtures of various metal-organic complexes.

Investigating the Electrochemically Driven Capture and Release of Long-Chain PFAS by Redox Metallopolymer Sorbents

The remediation of perfluoroalkyl substances (PFAS) is an urgent challenge due to their prevalence and persistence in the environment. Electrosorption is a promising approach for wastewater treatment and water purification, especially through the use of redox polymers to control the binding and release of target contaminants without additional external chemical inputs. However, the design of efficient redox electrosorbents for PFAS faces the significant challenge of balancing a high adsorption capacity while maintaining significant electrochemical regeneration. To overcome this challenge, we investigate redox-active metallopolymers as a versatile synthetic platform to enhance both electrochemical reversibility and electrosorption uptake capacity for PFAS removal. We selected and synthesized a series of metallopolymers bearing ferrocene and cobaltocenium units spanning a range of redox potentials to evaluate their performance for the capture and release of perfluorooctanoic acid (PFOA). Our results demonstrate that PFOA uptake and regeneration efficiency increased with more negative formal potential of the redox polymers, indicating possible structural correlations with the electron density of the metallocenes. Poly(2-(methacryloyloxy)ethyl cobaltoceniumcarboxylate hexafluorophosphate) (PMAECoPF₆) showed the highest affinity toward PFOA, with an uptake capacity of more than 90 mg PFOA/g adsorbent at 0.0 V vs Ag/AgCl and a regeneration efficiency of more than 85% at -0.4 V vs Ag/AgCl. Kinetics of PFOA release showed that electrochemical bias greatly enhanced the regeneration efficiency when compared to open-circuit desorption. In addition, electrosorption of PFAS from different wastewater matrices and a range of salt concentrations demonstrated the capability of PFAS remediation in complex water sources, even at ppb levels of contaminants. Our work showcases the synthetic tunability of redox metallopolymers for enhanced electrosorption capacity and regeneration of PFAS.

Mechanochemical upcycling of spent LiCoO2 to new LiNi0.80Co0.15Al0.05O2 battery: An atom economy strategy

The use of strong acids and low atom efficiency in conventional hydrometallurgical recycling of spent lithium-ion batteries (LIBs) results in significant secondary wastes and CO2 emissions. Herein, we utilize the waste metal current collectors in spent LIBs to promote atom economy and reduce chemicals consumption in a conversion process of spent Li1-xCoO2 (LCO) → new LiNi0.80Co0.15Al0.05O2 (NCA) cathode. Mechanochemical activation is employed to achieve moderate valence reduction of transition metal oxides (Co3+→Co2+,3+) and efficient oxidation of current collector fragments (Al0→Al3+, Cu0→Cu1+,2+), and then due to stored internal energy from ball-milling, the leaching rates of Li, Co, Al, and Cu in the ≤4 mm crushed products uniformly approach 100% with just weak acetic acid. Instead of corrosive precipitation reagents, larger Al fragments (≥4 mm) are used to control the oxidation/reduction potential (ORP) in the aqueous leachate and induce the targeted removal of impurity ions (Cu, Fe). After the upcycling of NCA precursor solution to NCA cathode powders, we demonstrate excellent electrochemical performance of the regenerated NCA cathode and improved environmental impact. Through life cycle assessments, the profit margin of this green upcycling path reaches about 18%, while reducing greenhouse gas emissions by 45%.

Interfacial Coordinational Bond Triggered Photoreduction Membrane for Continuous Light-Driven Precious Metals Recovery

Chemical/electric energy-driven processes dominate the traditional precious metal (PM) recovery market. The renewable energy-driven selective PM recycling approach crucial for carbon neutrality is under exploration. Herein, via an interfacial structure engineering approach, coordinational-active pyridine groups are covalently integrated onto the photoactive semiconductor SnS₂ surface to construct Py-SnS₂. Triggered by the preferred coordinational binding force between PMs and pyridine groups, together with the photoreduction capability of SnS₂, Py-SnS₂ shows significantly enhanced selective PM-capturing performance toward Au³⁺, Pd⁴⁺, and Pt⁴⁺ with recycling capacity up to 1769.84, 1103.72, and 617.61 mg/g for Au³⁺, Pd⁴⁺, and Pt⁴⁺, respectively. Further integrating the Py-SnS₂ membrane into a homemade light-driven flow cell, 96.3% recovery efficiency was achieved for continuous Au recycling from a computer processing unit (CPU) leachate. This study reported a novel strategy to fabricate coordinational bonds triggered photoreductive membranes for continuous PM recovery, which could be expanded to other photocatalysts for broad environmental applications.

Progress of Molecular Display Technology Using Saccharomyces cerevisiae to Achieve Sustainable Development Goals

In the long history of microorganism use, yeasts have been developed as hosts for producing biologically active compounds or for conventional fermentation. Since the introduction of genetic engineering, recombinant proteins have been designed and produced using yeast or bacterial cells. Yeasts have the unique property of expressing genes derived from both prokaryotes and eukaryotes. Saccharomyces cerevisiae is one of the well-studied yeasts in genetic engineering. Recently, molecular display technology, which involves a protein-producing system on the yeast cell surface, has been established. Using this technology, designed proteins can be displayed on the cell surface, and novel abilities are endowed to the host yeast strain. This review summarizes various molecular yeast display technologies and their principles and applications. Moreover, S. cerevisiae laboratory strains generated using molecular display technology for sustainable development are described. Each application of a molecular displayed yeast cell is also associated with the corresponding Sustainable Development Goals of the United Nations.

Ion Exchange Conversion of Na-Birnessite to Mg-Buserite for Enhanced and Preferential Cu2+ Removal via Hybrid Capacitive Deionization

Layered manganese oxides (LMOs) have recently been demonstrated to be one of the most promising redox-active material platforms for electrochemical removal of heavy metal ions from solution via capacitive deionization (CDI). However, the impact of interlayer spacing of LMOs on the deionization performance of electrodes in a hybrid capacitive deionization (HCDI) system with an LMO cathode and a carbon anode (i.e., LMO/C electrodes), and their phase transformation behaviors, particularly during the desalination operations, have yet to be extensively evaluated. In this study, we thoroughly evaluate Mg-buserite obtained by ion exchange of fresh Na-birnessite and Na- and K-birnessite as HCDI electrodes to remove copper ions (Cu²⁺) from saline solutions. Among the three LMO/C electrodes, the Mg-buserite/C (MgB/C) electrodes demonstrate the best deionization performance in terms of salt adsorption capacity (SAC), electrosorption rate, and cycling stability, followed by K-birnessite/C (KB/C) and Na-birnessite/C (NaB/C). More importantly, MgB/C exhibits the highest Cu²⁺ ion adsorption capacity (IAC) of 89.3 mg Cu²⁺ per gram electrode materials at a cell voltage of 1.2 V in 500 mg L^-1 CuCl₂ solution, with an IAC retention as high as 96.3% after 60 charge/discharge cycles. Given that electrosorption of Cu²⁺ ions is often competed by alkali and alkaline earth metal ions, our data reveal that the MgB/C electrodes demonstrate selectivities of 4.7, 7.7, and 8.1 for Cu²⁺ over Na⁺, Ca²⁺, and Mg²⁺, respectively. Moreover, X-ray diffraction and spectroscopic analyses show that the enhanced deionization performance and preference for Cu²⁺ are mainly attributed to the expanded interlayer spacing of LMO minerals. This study provides a promising strategy for tailoring LMO minerals for improving their electrosorption capacity and preference for copper ions from a multivalent-ion solution via an HCDI platform.

Electrochemical Methods for Water Purification, Ion Separations, and Energy Conversion

Agricultural development, extensive industrialization, and rapid growth of the global population have inadvertently been accompanied by environmental pollution. Water pollution is exacerbated by the decreasing ability of traditional treatment methods to comply with tightening environmental standards. This review provides a comprehensive description of the principles and applications of electrochemical methods for water purification, ion separations, and energy conversion. Electrochemical methods have attractive features such as compact size, chemical selectivity, broad applicability, and reduced generation of secondary waste. Perhaps the greatest advantage of electrochemical methods, however, is that they remove contaminants directly from the water, while other technologies extract the water from the contaminants, which enables efficient removal of trace pollutants. The review begins with an overview of conventional electrochemical methods, which drive chemical or physical transformations via Faradaic reactions at electrodes, and proceeds to a detailed examination of the two primary mechanisms by which contaminants are separated in nondestructive electrochemical processes, namely electrokinetics and electrosorption. In these sections, special attention is given to emerging methods, such as shock electrodialysis and Faradaic electrosorption. Given the importance of generating clean, renewable energy, which may sometimes be combined with water purification, the review also discusses inverse methods of electrochemical energy conversion based on reverse electrosorption, electrowetting, and electrokinetic phenomena. The review concludes with a discussion of technology comparisons, remaining challenges, and potential innovations for the field such as process intensification and technoeconomic optimization.

Lead electrodeposition from aliphatic polyamines solutions

Hydrometallurgical and pyrometallurgical processing of ores and concentrates generates large amount of various solid residues. These may contain significant amount of heavy metals, particularly lead is of great importance. It is present in form of anglesite, cerrusite or lead oxides. Hydrometallurgical processing of leaching residues, dusts, and fly ashes is used to recover valuable metals from these streams. Acid leaching in sulfuric acid solutions or spent electrolyte results in producing high amount of lead sulfate that is still very attractive material to fulfill demand of lead acid battery market. Aliphatic linear polyamines are solvent extracting agents very selective towards lead sulfate. Here we report the comparative tests of four different linear aliphatic homologs, namely ethylenediamine, diethylenetriamine, triethylenetetramine, and tetraethylenepentamine as potential extracting agents of lead sulfate. The core research was devoted to the possibility of direct electrodeposition of lead from various polyamines solutions. Electrochemical tests performed at current density 200 A/m2, 60 °C, with an addition of selected inhibitor showed the possibility to produce metal layer with 97.2% purity for triethylenetetramine.

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Selective cobalt and nickel electrodeposition for lithium-ion battery recycling through integrated electrolyte and interface control

Molecularly-selective metal separations are key to sustainable recycling of Li-ion battery electrodes. However, metals with close reduction potentials present a fundamental challenge for selective electrodeposition, especially for critical elements such as cobalt and nickel. Here, we demonstrate the synergistic combination of electrolyte control and interfacial design to achieve molecular selectivity for cobalt and nickel during potential-dependent electrodeposition. Concentrated chloride allows for the speciation control via distinct formation of anionic cobalt chloride complex (CoCl42-), while maintaining nickel in the cationic form ([Ni(H2O)5Cl]+). Furthermore, functionalizing electrodes with a positively charged polyelectrolyte (i.e., poly(diallyldimethylammonium) chloride) changes the mobility of CoCl42- by electrostatic stabilization, which tunes cobalt selectivity depending on the polyelectrolyte loading. This strategy is applied for the multicomponent metal recovery from commercially-sourced lithium nickel manganese cobalt oxide electrodes. We report a final purity of 96.4 ± 3.1% and 94.1 ± 2.3% for cobalt and nickel, respectively. Based on a technoeconomic analysis, we identify the limiting costs arising from the background electrolyte, and provide a promising outlook of selective electrodeposition as an efficient separation approach for battery recycling.