Influence of H2SO4 and ferric iron on Cd bioleaching from spent Ni-Cd batteries

Ultrasound-assisted efficient and convenient method of extracting valuable metals (Ni, Co, and Cd) from waste Ni-Cd batteries using DL-malic acid

Recycling waste Ni-Cd batteries has received much attention recently because of the serious environmental pollution they cause and to avoid the dissipation of valuable metals. Despite significant research, it is still difficult to efficiently recycle valuable and hazardous metals from waste Ni-Cd batteries in an economical and environmentally friendly manner. This study employed a novel process utilizing ultrasound-assisted leaching to recover Ni, Cd, and Co from waste nickel-cadmium (Ni-Cd) batteries. Organic DL-malic acid served as the leaching agent and H2O2 was employed as an oxidizing agent. The effects of various factors on the recovery efficiency of Ni, Cd, and Co, such as leaching temperature, time, DL-malic acid concentration, pulp density, H2O2 concentration, and ultrasound frequency, were also examined. To predict the chemical compounds present before and after the recycling experiments, the solid residues from the metal extraction were analyzed using XRD, XPS, FE-SEM, and EDS element mapping. Concurrently, ICP-OES was utilized to determine the metal content in the leachate. Under optimized conditions of 90 °C, 90 min, 2M DL-malic acid, 160 mL/g pulp density, and 20% ultrasound frequency, over 83% of Ni, 94% of Cd, and 98% of Co were effectively leached from the waste Ni-Cd battery powder. The leaching kinetics of Ni, Cd, and Co followed the surface chemical reaction control model. The activation energies (Ea) for Ni, Cd, and Co leaching were 21.34, 20.47, and 18.38 kJ/mol, respectively. The findings suggest that ultrasound-assisted leaching is an efficient, cost-effective, environmentally friendly, and sustainable alternative for extracting precious and hazardous metals from waste Ni-Cd batteries. Additionally, it reduces industrial chemical usage and enhances waste management sustainability.

A highly efficient process to enhance the bioleaching of spent lithium-ion batteries by bifunctional pyrite combined with elemental sulfur

Bioleaching technologies have been shown to be an environmentally friendly and economically beneficial tool for extracting metals from spent lithium-ion batteries (LIBs). However, conventional bioleaching methods have exhibited low efficiency in recovering metals from spent LIBs. Therefore, relied on the sustainability principle of using waste to treat waste, this study employed pyrite (FeS2) as an energy substance with reducing properties and investigated its effects in combination with elemental sulfur (S0) or FeSO4 on metals bioleaching from spent LIBs. Results demonstrated that the bioleaching efficiency was significantly higher in the leaching system constructed with FeS2 + S0, than in the FeS2 + FeSO4 or FeS2 system. When the pulp densities of FeS2, S0 and spent LIBs were 10 g L-1, 5 g L-1 and 10 g L-1, respectively, the leaching efficiency of Li, Ni, Co and Mn all reached 100%. Mechanistic analysis reveals that in the FeS2 + S0 system, the activity and acid-producing capabilities of iron-sulfur oxidizing bacteria were enhanced, promoting the generation of Fe (Ⅱ) and reducible sulfur compounds. Simultaneously, bio-acids were shown to disrupt the structure of the LIBs, thereby increasing the contact area between Fe (Ⅱ) and sulfur compounds containing high-valence metals. This effectively promoted the reduction of high-valence metals, thereby enhancing their leaching efficiency. Overall, the FeS2 + S0 bioleaching process constructed in this study, improved the leaching efficiency of LIBs while also effectively utilizing waste, providing technical support for the comprehensive and sustainable management of solid waste.

Metal bioleaching from printed circuit boards by bio-Fenton process: Optimization and prediction by response surface methodology and artificial intelligence models

Recycling printed circuit boards (PCBs) in the e-waste stream is essential for ecological protection and metal recycling for a circular economy. Efficient metal recovery from PCBs is highly dependent on the determination of the optimum combination of inputs in the recycling process. In this study, optimization and predictive modelling of the bio-Fenton process were performed employing the response surface methodology (RSM) and the artificial intelligence (AI) models for efficient enzymatic metal bioleaching from discarded cellphone PCBs. The Box-Behnken design (BBD) of RSM was chosen as the design matrix. Further, two AI models, i.e., support vector machine (SVM) and artificial neural network (ANN) were employed to predict complex metal bioleaching process. Experiments were performed based on variations of four input process parameters, namely, glucose oxidase (GOx) content (100-1000 U/L), Fe²⁺ content (10-50 mM), PCB pulp density (1-10 g/L), and shaking speed (150-450 rpm). Results revealed that the maximum simultaneous enzymatic metal extraction of 100% Cu, 70% Ni, 40% Pb, and 100% Zn was attained at the optimized conditions: GOx content: 300 U/L, Fe²⁺ content: 10 mM, pulp density: 1 g/L, and shaking speed: 335 rpm. A comparative analysis of the AI models suggested that the ANN-based model predicting more accurate results than the SVM-based model with coefficient of determination values > 0.99 for all the targeted metals. The FTIR analysis confirmed the partial disintegration of PCB polymeric base by OH radicals (OH•), which helped in liberating and exposing the embedded metals to the bio-Fenton solution. Further, the oxidation of metals by ferric ions produced from GOx-mediated oxidation of ferrous ions ensued efficient enzymatic metal bioleaching. Selective metal recovery of >99% was obtained by the chemical precipitation of bioleachate.

Complete bioleaching of Co and Ni from spent batteries by a novel silver ion catalyzed process

In the present work, bioleaching of two valuable metals of cobalt (Co) and nickel (Ni) from spent lithium-ion batteries (LIBs) of laptop by Acidithiobacillus ferrooxidans and Acidithiobacillus thiooxidans through a novel adaptation procedure was investigated. Different bioleaching methods including A. ferrooxidans and A. thiooxidans spent medium, A. ferrooxidans one-step and two-step bioleaching were carried out. The effect of silver ion on the bioleaching of Co and Ni in these methods was evaluated. Moreover, a novel strain adaptation approach to the toxic solid content of the battery powder was chosen, which resulted in a very short adaptation time and bioleaching (2 days). Even though silver ion did not have a significant effect on the spent medium method, it had an increasing effect of 26% and 7%, for Co and Ni recovery, respectively, on two-step bioleaching with silver ion-adapted A. ferrooxidans, in gradual addition of the battery powder. The highest extraction results in the spent medium method were 45.2% and 71.5% for Co and Ni, respectively, and a very high extraction yield of 99.95% for these metals was achieved in a short time of only 3 days by two-step bioleaching with gradual addition of the solid content and in the presence of Ag⁺. KEY POINTS: • Mixed spent medium of acidophilic bacteria resulted in higher Ni and Co extraction. • Adaptation to Ag⁺ has enhanced the strain capability for Co and Ni extraction. • With Ag⁺ presence, Co and Ni extraction reached 99.95% in two-step bioleaching.

Nickel and cadmium phytoextraction efficiencies of vetiver and lemongrass grown on Ni-Cd battery waste contaminated soil: A comparative study of linear and nonlinear models

A comparative assessment of the phytoremediation efficiency of two tolerant grass species viz. vetiver and lemongrass were performed in pots against simulated Ni-Cd battery electrolyte waste (EW) contaminated soil (EW1%, EW2% and EW4% w/w). Ni (μg g^-1) accumulation was higher in shoots (36.8) and roots (252.9) of vetiver than in lemongrass (12.5 and 79.7, respectively). While the same trend was true for Cd (μg g^-1) accumulation in vetiver and lemon grass roots (232.2 and 147.2, respectively), however, the accumulation in vetiver shoot (43.4) was less than in lemongrass (99.9). The bioaccumulation factor of metals in both grasses increased with EW contamination. Vetiver was tolerant towards EW toxicity than lemongrass, as it exhibited lesser decline in morphological parameters, lesser rise in TBARS against the doses of EW. The activities of SOD, APX, POD enzymes were higher in vetiver whereas, only GR in lemongrass. Multiple linear regression model show, pH had strong and positive influence over the Ni and Cd uptake by the plants whereas, phosphate, OM and bioavailable metals influenced negatively. The higher R² (>0.9) and Chi-square values ≤ 1 in sigmoid non-linear model demonstrates robustness of the model for predicting the Ni and Cd accumulation (M_HM) in both the grasses. Ni accumulation was higher than Cd, roots had greater accumulation of heavy metal and vetiver was a greater accumulator of Ni and Cd from EW the contaminated soil than lemongrass.

Bioleaching of critical metals from waste OLED touch screens using adapted acidophilic bacteria

The mobile phone is a fast-growing E-waste stream that includes hazardous substances and valuable metals. Smartphone touch screens (SPTS) contain a considerable amount of critical metals, such as indium and strontium that can be recovered from end of life devices as a secondary resource. Bioleaching is an emerging and environmentally friendly method for metal recovery from electronic waste. In the present study, bioleaching was assessed for the extraction of indium and strontium from organic light emitting diode type smartphone touch screens. A statistical approach based on the response surface methodology was successfully applied. The effects of influential variables: pH, ferrous sulfate, elemental sulfur, and solid content and their interactions on indium and strontium recovery using adapted Acidithiobacillus ferrooxidans were evaluated. Under optimum conditions (ferrous sulfate: 13.0 g/L; solid content; 3.0 g/L; elemental sulfur: 5.6 g/L; and initial pH of 1.1), a complete indium extraction was observed, with a concentration in solution of about 200 mg/L indium. As concerns strontium, a 5% extraction efficiency was observed, which, even if quite low, resulted in a relatively high strontium concentration in solution, around 3000 mg/L, due to its high content in the solid (2%). This work opens new perspectives in the application of clean technologies for the extraction of valuable metals, such as indium and strontium from smartphone screens.

Bioremediation of toxic heavy metals (THMs) contaminated sites: concepts, applications and challenges

Heavy metal contamination is a global issue, where the prevalent contaminants are arsenic (As), cadmium (Cd), chromium (Cr)(VI), mercury (Hg), and lead (Pb). More often, they are collectively known as "most problematic heavy metals" and "toxic heavy metals" (THMs). Their treatment through a variety of biological processes is one of the prime interests in remediation studies, where heavy metal-microbe interaction approaches receive high interest for their cost effective and ecofriendly solutions. In this review, we provide an up to date information on different microbial processes (bioremediation) for the removal of THMs. For the same, emphasis is put on oxidation-reduction, biomineralization, bioprecipitation, bioleaching, biosurfactant technology, biovolatilization, biosorption, bioaccumulation, and microbe-assisted phytoremediation with their selective advantages and disadvantages. Further, the literature briefly discusses about the various setups of cleaning processes of THMs in environment under ex situ and in situ applications. Lately, the study sheds light on the manipulation of microorganisms through genetic engineering and nanotechnology for their advanced treatment approaches.

Bioleaching of spent Zn-Mn or Ni-Cd batteries by Aspergillus species

This research explores the recovery of metals from spent Zn-Mn or Ni-Cd batteries by a bioleaching using six Aspergillus species. Two different nutrients, malt extract and sucrose, were used to produce different types of organic acids. Oxalic acid and citric acid were shown to be the dominant organic acid in malt extract and sucrose media, respectively. In the bioleaching, the metal removal was higher in sucrose media than malt extract. All species, except A. niger KUC5254, showed more than 90% removal of metals from Zn-Mn battery. For Ni-Cd battery, more than 95% of metals was extracted by A. niger KUC5254 and A. tubingensis KUC5037. As a result, A. tubingensis KUC5037 which is a non-ochratoxigenic fungus was considered to have the greatest potential for improving the safety and efficiency of the bioleaching.

End-of-life nickel-cadmium accumulators: characterization of electrode materials and industrial Black Mass

The aim of this paper is the characterization of spent NiCd batteries and the characterization of an industrial Black Mass obtained after crushing spent NiCd batteries and physical separation in a treatment plant. The characterization was first performed with five cylindrical NiCd batteries which were manually dismantled. Their characterization includes mass balance of the components, active powders elemental analysis and phase identification by X-ray powder diffraction. Chemical speciation of the two metals was also investigated. For cadmium, speciation was previously developed on solid synthetic samples. In a spent battery, the active powders correspond to about 43% of the battery weight. The other components are the separator and polymeric pieces (5%), the support plates (25%) and the carbon steel external case (27%). The sequential procedure shows that the nickel in the positive powders from the dismantled Ni-Cd batteries is distributed between Ni0 (39.7%), Ni(OH)2 (58.5%) and NiOOH (1.8%). Cadmium in the negative powder is about 99.9% as the Cd(OH)2 form with 0.1% of metal cadmium. In the industrial Black Mass, the distribution of cadmium is the same, whereas the distribution of nickel is Ni0 (46.9%), Ni(OH)2 (43.2%) and NiOOH (9.9%). This material contains also 1.8% cobalt and approx. 1% iron.

Removal of nickel and cadmium from battery waste by a chemical method using ferric sulphate

The removal of nickel (Ni) and cadmium (Cd) from spent batteries was studied by the chemical method. A novel leaching system using ferric sulphate hydrate was introduced to dissolve heavy metals in batteries. Ni-Cd batteries are classified as hazardous waste because Ni and Cd are suspected carcinogens. More efficient technologies are required to recover metals from spent batteries to minimize capital outlay, environmental impact and to respond to increased demand. The results obtained demonstrate that optimal conditions, including pH, concentration of ferric sulphate, shaking speed and temperature for the metal removal, were 2.5, 60 g/L, 150 rpm and 30 degrees C, respectively. More than 88 (+/- 0.9) and 84 (+/- 2.8)% of nickel and cadmium were recovered, respectively. These results suggest that ferric ion oxidized Ni and Cd present in battery waste. This novel process provides a possibility for recycling waste Ni-Cd batteries in a large industrial scale.