Investigation of optimal conditions for zinc electrowinning from aqueous sulfuric acid electrolytes

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 Kinetically Superior Rechargeable Zinc-Air Battery Derived from Efficient Electroseparation of Zinc, Lead, and Copper in Concentrated Solutions

Zinc electrodeposition is currently a hot topic because of its widespread use in rechargeable zinc-air batteries. However, Zn deposition has received little attention in organic solvents with much higher ionic conductivity and current efficiency. In this study, a Zn-betaine complex is synthesized by using ZnO and betainium bis[(trifluoromethyl)sulfonyl]imide and its electrochemical behavior for six organic solvents and electrodeposited morphology are studied. Acetonitrile allowed dendrite-free Zn electrodeposition at room temperature with current efficiencies of up to 86 %. From acetonitrile solutions in which Zn, Pb, and Cu complexes are dissolved in high concentrations, Zn and Pb/Cu are efficiently separated electrolytically under potentiostatic control, allowing the purification of solutions prepared directly from natural ores. Additionally, a highly flexible Zn anode with excellent kinetics is obtained by using a carbon fabric substrate. A rechargeable zinc-air battery with these electrodes shows an open-circuit voltage of 1.63 V, is stable for at least 75 cycles at 0.5 mA cm^-2 or 33 cycles at 20 mA cm^-2 , and allows intermediate cycling at 100 mA cm^-2 .

Ionometallurgical Step-Electrodeposition of Zinc and Lead and its Application in a Cycling-Stable High-Voltage Zinc-Graphite Battery

Ionometallurgy is a new development aiming at the sustainable low-temperature conversion of naturally occurring metal ores and minerals to their metals or valuable chemicals in ionic liquids (ILs) or deep eutectic solvents. The IL betainium bis((trifluoromethyl)sulfonyl)imide, [Hbet][NTf₂ ], is especially suited for this process due to its redox-stability and specific-functionalization. The potentiostatic electrodeposition of zinc and lead starting directly from ZnO and PbO, which dissolve in [Hbet][NTf₂ ] in high concentrations is reported. The initial reduction potentials of zinc(II) and lead(II) are about -1.5 and -1.0 V, respectively. The ionic conductivity of the solution of ZnO in [Hbet][NTf₂ ] is measured and the effect of various temperatures and potentials on the morphology of the deposited material is explored. The IL proves to be stable under the chosen conditions. From IL-solutions, where ZnO, PbO, and MgO have been dissolved, metallic Zn and Pb are deposited under potentiostatic control either consecutively by step-electrodeposition or together in a co-electrodeposition. Using the method, Zn is also deposited on 3D copper foam and assembles into high-voltage zinc-graphite battery. It exhibits a working-voltage up to 2.7 V, an output midpoint discharge-voltage of up to 2.16 V, up to 98.6% capacity-retention after 150 cycles, and good rate performance.

A perspective of stepwise utilization of hazardous zinc plant purification residue based on selective alkaline leaching of zinc

A new route for selective recovery of zinc from hazardous zinc plant purification residue was proposed by alkaline leaching process. The thermodynamic analysis revealed that by controlling solution pH in the range from 14.30 to 16.78 at 25 °C, basic zinc sulfate can be converted to ZnO₂^2- instead of Zn(OH)₂, while Cd will enter into alkaline leaching residue as a hydroxide. It is feasible to leach selectively Zn and to separate it with Cd by alkaline leaching, and the experimental results confirm that. Under the conditions of NaOH concentration of 3 mol/L, L/S of 20 ml/g, temperature of 40 °C, and time of 50 min, LR of Zn reached 96.14% while them of Pb and Cd were only 0.66% and 2.83% respectively. ZnO with hexagonal wurtzite structure and Cd(OH)₂ were the main phases of leaching residue. They crystallized and adhered to the surface of leaching residue particles, which result in the loose and random particle morphology. The findings confirm that alkaline leaching is efficient in separation of Zn and Cd in ZPPR. In addition, nano-ZnO with flowerlike was synthesized with the zinc-rich leaching solution by precipitation method and the its photocatalytic property was similar to that of nano-ZnO purchased.

Recovery of Metals from Secondary Raw Materials by Coupled Electroleaching and Electrodeposition in Aqueous or Ionic Liquid Media

This paper presents recent views on a hybrid process for beneficiation of secondary raw materials by combined electroleaching of targeted metals and electrodeposition. On the basis of several case studies with aqueous solutions or in ionic liquid media, the paper describes the potential and the limits of the novel, hybrid technique, together with the methodology employed, combining determination of speciation, physical chemistry, electrochemistry, and chemical engineering. On one hand, the case of electroleaching/electrodeposition (E/E) process in aqueous media, although often investigated at the bench scale, appears nevertheless relatively mature, because of the developed methodology, and the appreciable current density allowed, and so it can be used to successfully treat electrode materials of spent Zn/MnO2 batteries or Ni/Cd accumulators and Waelz oxide. On the other hand, the use of ionic liquids as promising media for the recovery of various metals can be considered for other types of wastes, as shown here for the case of electrodes of aged fuel cells. The combined (E/E) technique could be successfully used for the above waste, in particular by the tricky selection of ionic liquid media. Nevertheless, further investigations in physical chemistry and chemical engineering appear necessary for possible developments of larger-scale processes for the recovery of these strategic resources.