Thermal treatment for recovery of manganese and zinc from zinc-carbon and alkaline spent batteries

Direct recovery of Zn from wasted alkaline batteries through selective anode's separation

In the present study, a leaner process for recovering zinc from spent alkaline batteries is studied at a laboratory scale. Such process is part of a diagram, under development, that aims at maximizing the value of all the battery components while reducing the costs of treatment and the environmental footprint involved in recycling this waste. It starts by a physical and selective pre-treatment stage that separates the anode from the remaining components followed by neutral leaching (three washing cycles at room temperature, S/L ratio of 1/5 (w/v), magnetic stirring for 15 min and settling during 45 min), acid leaching of the washed solid (4 mol/L of sulphuric acid, S/L ratio of 1/3 (w/v), 120 min at room temperature under magnetic stirring) and, finally, electrowinning of zinc from the pregnant leach solution (100 mA/cm², 120 min under slow magnetic stirring). By leaching the anode alone, it is possible to obtain a solution rich in zinc (86 g/L), with very low concentration of other metals (<0.08 g/L). Such solution was adequate for zinc electrowinning, allowing an average recovery rate of 58%, without applying any purification stages, at the same time regenerating sulphuric acid for its recirculation. In conclusion, the results demonstrate that a more specific physical pre-treatment stage is highly desirable to recycle spent alkaline batteries in order to reduce the number of stages involved and the overall complexity, thus, reducing the costs involved and the potential environmental impacts, while maintaining high recovery rates of zinc.

A novel process on the recovery of zinc and manganese from spent alkaline and zinc-carbon batteries

Spent alkaline and zinc-carbon batteries contain valuable elements (notably, Zn and Mn), which need to be recovered to keep a circular economy. In this study, the black mass materials from those spent batteries are pyrometallurgically treated via a series of process steps in a pilot-scale KALDO furnace to produce an Mn-Zn product, a ZnO product, and an MnO (manganese monoxide) product, toward applications of Mn-Zn micronutrient fertilizer, zinc metal, and manganese alloy, respectively. After an oxidative roasting step, an Mn-Zn product, containing 43% Mn, 22% Zn, and negligible amounts of toxic elements (notably, Cd, Hg, and Pb), could be produced, being suitable for the micronutrient fertilizer application. After a reductive roasting step, a ZnO product and an MnO product are produced. The attained ZnO product, containing up to 84.6% ZnO, is suitable for zinc metal production when the leaching steps are taken to remove most of the Cl and F in the product. The attained MnO product, containing up to 91.7% MnO, is of premium quality for manganese alloy production, preferably for SiMn alloy production due to its low phosphorus content. The proposed application scenarios could substantially improve the recovery efficiency of those spent batteries.

Manganese oxide synthesized from spent Zn-C battery for supercapacitor electrode application

Manganese oxide (Mn₃O₄) nanomaterials have promising potential to be used as supercapacitor electrode materials due to its high energy storage performance and environmental compatibility. Besides, every year huge volume of waste batteries including Zn-C battery ends up in landfill, which aggravates the burden of waste disposal in landfill and creates environmental and health threat. Thus, transformation of waste battery back into energy application, is of great significance for sustainable strategies. Compared with complex chemical routes which mostly apply toxic acids to recover materials from Zn-C battery, this study establishes the recovery of Mn₃O₄ particles via thermal route within 900 °C under controlled atmosphere. Synthesized Mn₃O₄ were confirmed by XRD, EDS, FTIR, XPS and Raman analysis and FESEM micrographs confirmed the coexistence of spherical and cubic Mn₃O₄ particles. Mn₃O₄ electrode derived from waste Zn-C battery demonstrate compatible electrochemical performance with standard materials and conventional synthesis techniques. Mn₃O₄ electrode exhibited highest capacitance value of 125 Fg⁻¹ at 5 mVs⁻¹ scan rate. The stability of the electrode showed good retention in discharge and charge capacity by about 80% after 2100 cycles. This study demonstrates that waste Zn-C battery can be further utilized for energy storage application, providing sustainable and economic benefits.

Synthesis of novel waste batteries-sawdust-based adsorbent via a two-stage activation method for Pb2+ removal

The novel waste alkaline battery-sawdust-based adsorbents (WABAs) are prepared by a two-stage activation method with the negative electrode materials as activator and different doping ratio of the positive electrode materials and pine sawdust as raw materials. The characteristics of the WABAs are analyzed by SEM, XRD, FT-IR, and specific surface determination (S_BET). The Pb²⁺ adsorption properties of the WABAs are studied by changing the pH of solution, contact time, initial concentration, and temperature. It turns out that when the doping mass ratio is 1:4, the optimum performance of the WABAs is obtained, and comparing with the samples prepared by pure biomass, the iodine adsorption value, total acid groups, and cation exchange capacity (CEC) separately increased by 13, 106, and 22%, respectively. Kinetic studies show that the pseudo-second-order model is more suitable for describing the Pb²⁺ adsorption process and the Langmuir isotherm provides better fitting to the equilibrium data. The thermodynamic parameters indicate the adsorption process would be spontaneous and endothermic. Besides, the prepared WABAs could be reused for 5 cycles with high removal efficiency. This study provides an alternative route for waste alkaline battery treatment. Graphical abstract The schematic diagram of synthesis of waste batteries-sawdust-based adsorbent via a two-stage activation method for Pb²⁺ removal.

From spent alkaline batteries to ZnxMn3−xO4 by a hydrometallurgical route: synthesis and characterization

A series of Zn/Mn binary oxides with different molar ratios were synthesized via co-precipitation from a solution obtained through the leaching of a black mass originating from the mechanical recycling of spent alkaline and Zn–C batteries.

Simultaneous recovery of Zn and Mn from used batteries in acidic and alkaline mediums: A comparative study

A parallel study of acidic and alkaline leaching for the recovery of Mn and Zn from spent alkaline batteries is outlined. Using H₂SO₄ as solvent and selecting appropriate conditions of temperature and concentration, all residues were dissolved except carbon. The separation and recovery of the two components were performed by electrodeposition with satisfactory results at pH values above 4 (current efficiency above 70% for Zn and Mn) but rather lower efficiencies as the pH decreased. Most of the Zn was selectively dissolved by alkaline leaching using a 6.5M NaOH solution, and its recovery was examined by means of both electrochemical and chemical processes. The expected formation of pure Zn by electrowinning failed due to the formation of ZnO, the content of which was highly dependent on the electrodeposition time. For short periods, Zn was the main component. For longer periods the electrodeposit consisted of agglomerated microparticles of ZnO with a minor fraction of Zn metal (barely 3% as measured by X-ray diffraction). A chemical reaction of the element with oxygen released at the anode surface might be responsible for its conversion to ZnO. A simple chemical route is described for the first time for the direct conversion of Zn(OH)₄^2- solution to nanostructured ZnO by lowering the pH to values around 12 using 2M HCl solution.

Utilization of automotive shredder residues in a thermal process for recovery of manganese and zinc from zinc-carbon and alkaline spent batteries

The aim of the study is the recovery by thermal treatment of manganese and zinc from a mixture of zinc-carbon and alkaline spent batteries, on the basis of the different phase change temperatures of the two metal-bearing phases. ASR (Automotive Shredder Residue), containing 68% of carbon, was added to the mixture to act as a reductant to metallic Zn of the zinc-bearing phases. The mixture was subsequently heated in different atmospheres (air, CO2 and N2) and at different temperatures (900°C, 1000°C and 1200°C) and stoichiometric excess of ASR (300%, 600% and 900%). Characterization of the mixture and of the residues of thermal treatment was carried out by chemical analysis, TGA/DTA, SEM and XRD. The results show that recovery of 99% of zinc (grade 97%) is achieved at 1000°C in N2 with a stoichiometric excess of car-fluff of 900%. This product could be suitable for production of new batteries after refining by hydrometallurgical way. Recovery of Mn around 98% in the residue of the treatment is achieved at any temperature and atmosphere tested with a grade of 57% at 900% excess of car-fluff. This residue is enriched in manganese oxide and could be used in the production of iron-manganese alloys.

Production of zinc and manganese oxide particles by pyrolysis of alkaline and Zn-C battery waste

Production of zinc and manganese oxide particles from alkaline and zinc-carbon battery black mass was studied by a pyrolysis process at 850-950°C with various residence times under 1L/minN2(g) flow rate conditions without using any additive. The particular and chemical properties of the battery waste were characterized to investigate the possible reactions and effects on the properties of the reaction products. The thermodynamics of the pyrolysis process were studied using the HSC Chemistry 5.11 software. The carbothermic reduction reaction of battery black mass takes place and makes it possible to produce fine zinc particles by a rapid condensation, after the evaporation of zinc from a pyrolysis batch. The amount of zinc that can be separated from the black mass is increased by both pyrolysis temperature and residence time. Zinc recovery of 97% was achieved at 950°C and 1h residence time using the proposed alkaline battery recycling process. The pyrolysis residue is mainly MnO powder with a low amount of zinc, iron and potassium impurities and has an average particle size of 2.9μm. The obtained zinc particles have an average particle size of about 860nm and consist of hexagonal crystals around 110nm in size. The morphology of the zinc particles changes from a hexagonal shape to s spherical morphology by elevating the pyrolysis temperature.

Recovery of manganese and zinc from spent Zn-C cell powder: Experimental design of leaching by sulfuric acid solution containing glucose

The spent Zn-C cell powder, containing ZnMn2O4, ZnO, MnO(OH) and possibly Mn2O3 and Mn3O4, can be leached by a sulfuric acid solution mixed with some glucose. The leaching is found to be dependent on solid to liquid (S/L) ratio, amount of glucose, concentration of sulfuric acid solution, time and pulp agitation speed. For 5g powder (S), 1h leaching time and 300rpm pulp agitation speed, two-level four-factor (2(4)) experimental designs have been carried out to derive models for extraction of both Mn(II) and Zn(II). Amount of glucose (G, g), concentration of H2SO4 solution (C, mol/L), volume of H2SO4 solution as leachant (L, mL) and leaching temperature (T, °C) are considered as factors (variables). The model in both cases consists of mean, factor effects and interaction effects. The four-factor interaction effect is observed in neither of the cases. Some two-factor and three-factor effects are found to have produced positive or negative contributions to dissolution percentage in both cases. The models are examined for comparison with experimental results with good fits and also used for optimization of factors. At optimized condition (G=0.50g, C=2mol/L, L=250mL and T=100°C), an aliquot of 5g powder in 1h and at 300rpm produces a solution containing (7.08±0.10)g/L Mn(II) and (2.20±0.06)g/L Zn(II) corresponding to almost 100% extraction of both metal ions.

Recovery of manganese and zinc from waste Zn-C cell powder: Mutual separation of Mn(II) and Zn(II) from leach liquor by solvent extraction technique

Acidic organophosphorous extractants were screened for the mutual separation of Mn(II) and Zn(II), in a leach solution of waste Zn-C cell powder. This was done using a 2mol/L H2SO4 solution containing 2g/L glucose. Extraction characteristics of both metal ions in this mixture have been examined as functions of equilibrium pH. Although tech. and anal. grade D2EHPA are not so effective for the separation, PC88A, Cyanex 272, Cyanex 302 and Cyanex 301 are all promising for this purpose. Strippings of Mn(II) and Zn(II) from the extracted organic phases have been examined, using 0.25, 0.50 and 1mol/L H2SO4; and 1mol/L HCl, HNO3 and HClO4 at different phase ratios. H2SO4 appears to be the best stripping agent. A 1mol/L H2SO4 solution strips almost 100% of target metal ions in 10min, regardless of the extractant used. As ΔpH1/2=2.75 and as the max. separation factor (β)=1793 for Cyanex 302 at pH(eq)=4.0, a flow sheet has been developed for their mutual separations. Finally, classical precipitation methods have been adopted to obtain MnS and ZnS, which can be easily oxidized to MnO2 and ZnO, respectively.

Characterization of the products attained from a thermal treatment of a mix of zinc-carbon and alkaline batteries

This study applies a thermal separation process (TSP) to recover Fe, Mn, and Zn from hazardous spent zinc-carbon and alkaline batteries. In the TSP, the batteries were heated together with a reducing additive and the metals in batteries, according to their boiling points and densities, were found to move into three major output materials: slag, ingot (mainly Fe and Mn), and particulate (particularly Zn). The slag well encapsulated the heavy metals of interest and can be recycled for road pavement or building materials. The ingot had high levels of Fe (522,000 mg/kg) and Mn (253,000 mg/kg) and can serve as an additive for stainless steel-making processes. The particulate phase had a Zn level of 694,000 mg/kg which is high enough to be directly sold for refinement. Overall, the TSP effectively recovered valuable metals from the hazardous batteries.

Recovery of manganese and zinc from waste Zn-C cell powder: Characterization and leaching

A large number of waste Zn-C cells (Haquebrand) were broken down and collected as agglomerated powder. This powder was sun-dried, dry-ground and sieved down to 300 mesh size and stored. The sample was analysed and found to contain (35.4 ± 0.2)% Mn, (11.0 ± 0.1)% Zn and ∼ 2.5% Fe as major metallic constituents. The phases, ZnMn2O4 and Zn(ClO4)2 · 2H2O or MnO(OH) were identified in the hot water washed sample. The material was found to be leached effectively by a 2 mol/L sulfuric acid solution containing glucose (2g/L). However, the dissolution was dependent on (S/L) ratio; and the stage-wise leaching was not fruitful for Mn-dissolution. On leaching 5 g of powder (<53 μm) with a 250 mL of 0.5 g glucose containing 2 mol/L sulfuric acid solution (S/L=20 g/L), at 100°C and 300 rpm for 1h, a solution containing (7.08 ± 0.10)g/L Mn(2+), (2.20 ± 0.06) Zn(2+) and ∼ 0.40 g/L Fe(3+) was recovered corresponding to cent percent dissolutions of Zn and Mn and 80% dissolution of Fe.

Reclaiming the spent alkaline zinc manganese dioxide batteries collected from the manufacturers to prepare valuable electrolytic zinc and LiNi0.5Mn1.5O4 materials

A process for reclaiming the materials in spent alkaline zinc manganese dioxide (Zn-Mn) batteries collected from the manufacturers to prepare valuable electrolytic zinc and LiNi0.5Mn1.5O4 materials is presented. After dismantling battery cans, the iron cans, covers, electric rods, organic separator, label, sealing materials, and electrolyte are separated through the washing, magnetic separation, filtrating, and sieving operations. Then, the powder residues react with H2SO4 (2 mol L(-1)) solution to dissolve zinc under a liquid/solid ratio of 3:1 at room temperature, and subsequently, the electrolytic Zn with purity of ⩾99.8% is recovered in an electrolytic cell with a cathode efficiency of ⩾85% under the conditions of 37-40°C and 300 A m(-2). The most of MnO2 and a small quantity of electrolytic MnO2 are recovered from the filtration residue and the electrodeposit on the anode of electrolytic cell, respectively. The recovered manganese oxides are used to synthesize LiNi0.5Mn1.5O4 material of lithium-ion battery. The as-synthesized LiNi0.5Mn1.5O4 discharges 118.3 mAh g(-1) capacity and 4.7 V voltage plateau, which is comparable to the sample synthesized using commercial electrolytic MnO2. This process can recover the substances in the spent Zn-Mn batteries and innocuously treat the wastewaters, indicating that it is environmentally acceptable and applicable.