Studies of Selective Recovery of Zinc and Manganese from Alkaline Batteries Scrap by Leaching and Precipitation

Recovery of zinc and manganese from scrapped alkaline batteries were carried out in the following way: leaching in H₂SO₄ and selective precipitation of zinc and manganese by alkalization/neutralization. As a result of non-selective leaching, 95.6-99.7% Zn was leached and 83.7-99.3% Mn was leached. A critical technological parameter is the liquid/solid treatment (l/s) ratio, which should be at least 20 mL∙g^-1. Selective leaching, which allows the leaching of zinc only, takes place with a leaching yield of 84.8-98.5% Zn, with minimal manganese co-leaching, 0.7-12.3%. The optimal H₂SO₄ concentration is 0.25 mol∙L^-1. Precipitation of zinc and manganese from the solution after non-selective leaching, with the use of NaOH at pH = 13, and then with H₂SO₄ to pH = 9, turned out to be ineffective: the manganese concentrate contained 19.9 wt.% Zn and zinc concentrate, and 21.46 wt.% Mn. Better selectivity results were obtained if zinc was precipitated from the solution after selective leaching: at pH = 6.5, 90% of Zn precipitated, and only 2% manganese. Moreover, the obtained concentrate contained over 90% of ZnO. The precipitation of zinc with sodium phosphate and sodium carbonate is non-selective, despite its relatively high efficiency: up to 93.70% of Zn and 4.48-93.18% of Mn and up to 95.22% of Zn and 19.55-99.71% Mn, respectively for Na₃PO₄ and Na₂CO₃. Recovered zinc and manganese compounds could have commercial values with suitable refining processes.

Recovery of Tantalum and Manganese from Epoxy-Coated Solid Electrolyte Tantalum Capacitors through Selective Leaching and Chlorination Processes

Electronic products are ever growing in popularity, and tantalum capacitors are heavily used in small electronic products. Spent epoxy-coated solid electrolyte tantalum capacitors, containing about 22 wt.% of tantalum and 8 wt.% of manganese, were treated with selective leaching by hydrochloric acid and chlorination after removing the epoxy resin, and the products converted, respectively, to Mn(OH)₂ and TaCl₅. The effects of acid type, acid concentration, liquid–solid ratio, and reaction time were investigated to dissolve the manganese. The optimal selective leaching conditions were determined as 3 mol/L of HCl, 40 mL/g at 25 °C for 32 min. Next, residues of selective leaching after washing and drying were heated with ferrous chloride to convert to pure TaCl₅. Mixing 48 wt.% of chloride and 52 wt.% of residues for a total of 5 g was conducted to complete the chlorination process in the tube furnace at 450 °C for 3 h. A total of 2.35 g of Ta was collected and the recovery of Ta achieved 94%. Finally, Mn(OH)₂ and TaCl₅ were separated and purified as the products.

A critical updated review of the hydrometallurgical routes for recycling zinc and manganese from spent zinc-based batteries

This review paper aims to present and analyse data from the most recent literature (between 2007 and 2019) published on the topic of manganese (Mn) and zinc (Zn) recovery from zinc-based spent batteries through hydrometallurgical methods. In a first attempt, a detailed comparative assessment of the metals leaching performance (as well as the experimental variables that influence its performance) reported in the various studies with strong acid or bases, potentially supplemented by complexing or reducing agents, as well as the reactions involved, are reviewed and discussed. All data point out that the use of a reductant is needed to fully solubilize Mn from spent batteries during the leaching process. Comparison of the data seem to indicate that most reductants have similar performance and, therefore, the choice of a reductant should be focused on low cost or even waste materials. In a second attempt, the separative processes mostly described in the literature to recover Mn and Zn from leachates are reviewed emphasizing the strengths and weaknesses of each technique. Solvent extraction is the most widely tested process for this aim. A thorough comparison of existing data indicates that, in general, neutral extractants have higher potential for selective separation of Zn and Mn. Furthermore, although chemical precipitation is a simple process, low pure final metal hydroxide products are expected to be achieved when alkaline precipitation is implemented comparatively to the Mn oxidative precipitation where Mn can be recovered selectively as a solid of manganese (IV) oxide.

Energy efficient electrodes for lithium-ion batteries: Recovered and processed from spent primary batteries

In an attempt to develop low cost, energy efficient and advanced electrode material for lithium-ion batteries (LIBs), waste-to-wealth derived as well as value added spent battery materials as potential alternatives assume paramount importance. By combining the low lithiation potential advantages, one can arrive at energy efficient electrodes bestowed with cost effective and eco-friendly benefits required for practical LIB applications. In the present study, Zn and Mn-salts along with C were successfully extracted from the spent zinc carbon batteries through a simple and efficient hydrometallurgy approach and decomposed thermally to obtain ZnMn₂O₄ at 350 °C for 12 h and 450 °C for 3 h. Further, C-ZnMn₂O₄ nanocomposites were prepared and demonstrated for appreciable electrochemical performance in LIB assembly. Our results show that C-ZnMn₂O₄ composites prepared at 350 °C and 450 °C demonstrate better performance than pristine ZnMn₂O₄ anode due to the improved electronic conductivity rendered by the added carbon obtained from spent primary battery. In particular, C-ZnMn₂O₄ at 350 °C @12 h exhibits appreciable electrochemical performance by showing a stable and higher capacity of 600 mAhg^-1 at a current density of 50 mAg^-1 in the voltage range of 0.01-3.0 V and qualifies it as a better performing cost-effective anode for LIBs.

Recycling of Alkaline Batteries via a Carbothermal Reduction Process

Primary battery recycling has important environmental and economic benefits. According to battery sales worldwide, the most used battery type is alkaline batteries with 75% of market share due to having a higher performance than other primary batteries such as Zn–MnO2. In this study, carbothermal reduction for zinc oxide from battery waste was completed for both vacuum and Ar atmospheres. Thermodynamic data are evaluated for vacuum and Ar atmosphere reduction reactions and results for Zn reduction/evaporation are compared via the FactSage program. Zn vapor and manganese oxide were obtained as products. Zn vapor was re-oxidized in end products; manganese monoxide and steel container of batteries are evaluated as ferromanganese raw material. Effects of carbon source, vacuum, temperature and time were studied. The results show a recovery of 95.1% Zn by implementing a product at 1150 °C for 1 h without using the vacuum. The residues were characterized by Atomic Absorption Spectrometer (AAS) and X-ray Diffraction (XRD) methods.

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.

Selective leaching of Zn from spent alkaline batteries using environmentally friendly approaches

The main aim of this work was to evaluate the possibility of using microwave or ultrasound to assist the efficient and selective leaching of Zn from spent alkaline batteries and compare the results with those obtained using the conventional method. Two different strategies were applied: acid leaching of a washed residue and alkaline leaching of the original residue. In both (acid and alkaline) approaches, the use of microwave- or ultrasound-assisted leaching increased the extraction of Zn compared with the best results obtained using conventional leaching [acid leaching (1.5mol/L H₂SO₄, 3h, 80°C), 90% of Zn extracted; alkaline leaching (6mol/L NaOH, 3h, 80°C), 42% of Zn extracted]. With acid leaching, 94% of the Zn was extracted using microwave-assisted leaching (1 cycle, 30s, 1mol/L H₂SO₄), and 92% of the Zn was extracted using ultrasound-assisted leaching (2min, 0.1p, 20% amplitude, 1mol/L H₂SO₄). Ultrasound-assisted leaching resulted in a more selective (Zn/Mn ratio of 5.1) Zn extraction than microwave-assisted leaching (Zn/Mn ratio of 3.5); both processes generated a concentrated Zn solution (⩾18.7g/L) with a purity (83.3% and 77.7%, respectively) that was suitable for electrowinning. With alkaline leaching, microwave- (1 cycle, 3 min, 4mol/L NaOH) and ultrasound-assisted (14min, 0.1p, 20% amplitude, 4mol/L NaOH) leaching extracted about 80% of the Zn and less than 0.01% of the Mn, which resulted in lesser concentrated Zn solutions (approximately 16.5g/L) but with high purity (>99.5%) that was suitable for the recovery of Zn by precipitation. The microwave- and ultrasound-assisted leaching strategies used in this work proved to be efficient and environmentally-friendly approaches for the extraction of Zn from spent alkaline residues since a concentrated Zn solution with adequate purity for subsequent Zn recovery was obtained using significantly decreased leaching times and concentrations of chemicals.

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.