Method for Increasing Recycled Manganese Content

Patent metadata

Field	Value
Publication number	US-2019115601-A1
Application number	US-201816218955-A
Country	US
Kind code	A1
Filing date	Dec 13, 2018
Priority date	Jun 21, 2017
Publication date	Apr 18, 2019
Grant date	—

Abstract

Methods of recycling batteries are provided, in which reaction conditions and elements are designed to maximize manganese recovery while minimizing zinc and potassium impurities in the recovered manganese. Methods of treating waste solution created by washing the manganese, so as to remove zinc from the waste solution, are also provided. Batteries prepared via such methods are also provided.

First claim

1 . A battery produced using a process for removing potassium from an aqueous solution, said process comprising:
a) reacting potassium sulfate with ferric sulfate so as to form potassium jarosite, wherein the iron:potassium ratio is no greater than about 20:1.

2 . The battery of claim 1 , wherein the iron:potassium ratio is no greater than about 15:1.

3 . The battery of claim 1 , wherein the reaction occurs at a pH of about 1.8 to about 2.0.

4 . The battery of claim 1 , wherein the aqueous solution is a sulfuric acid solution.

5 . The battery of claim 1 , wherein the iron:potassium ratio is about 11.5:1.

6 . A battery produced using a process for reducing the amount of fresh water required to recycle a plurality of batches of recovered battery material, said process comprising the steps of:
a) contacting manganese oxide solids comprising zinc and impurities with an acidic solution, so as to produce a waste solution comprising impurities; b) raising the pH of the waste solution to at least 9.0 so as to cause a portion of the impurities to precipitate; c) removing precipitated impurities; and d) after removing the precipitated impurities, using the waste solution to wash additional recovered battery material; wherein the impurities comprise zinc or potassium impurities.

7 . The battery of claim 6 , wherein in step b) the pH is raised to at least 10.0.

8 . The battery of claim 6 , wherein in step b) the pH is raised by adding NaOH.

9 . The battery of claim 6 , wherein the process further comprises reducing the pH of the waste solution prior to step d).

10 . The battery of claim 6 , wherein the acidic solution is a sulfuric acid solution.

11 . (canceled)

12 . A battery produced using a process for recycling batteries, said process comprising the steps of:
a) separating active materials contained within battery cases from the battery cases, wherein the active materials comprise fine electrode powders of manganese oxides; b) extracting residual zinc and potassium compounds from the fine electrode powders to obtain a purified manganese oxide product; wherein step b) is performed using waste solution previously generated in the course of recycling batteries; and wherein the waste solution has been treated to remove zinc by the addition of NaOH.

13 . The battery of claim 12 , wherein step b) is performed in an aqueous solution or aqueous slurry at a pH of less than or about 1.5.

14 . The battery of claim 12 , wherein step a) is carried out using a water spray to obtain a slurry of the fine electrode powders and pieces of the battery cases.

15 . The battery of claim 12 , wherein the separation in step a) comprises sieving the active materials and the battery cases through a screen to separate the active materials from the battery cases.

16 . The battery of claim 12 , wherein during step a) the active materials are present in the form of an aqueous slurry having a pH of greater than 8.

17 . The battery of claim 12 , wherein the purified manganese oxide product from step b) is roasted at 350-400° C. to remove substantially all volatile or corrosive impurities or traces of mercury prior to calcinating the purified manganese oxide product at 850° C. or higher.

18 . The battery of claim 12 , wherein the liquid to solid ratio during step c) is between about 12:1 to about 14:1.

19 . The battery of claim 12 , wherein the aqueous solution or aqueous slurry comprises sulfuric acid.

20 . (canceled)

Assignees

• Energizer Brands Llc

Inventors

• Slezak Philip J

Classifications

• H01M6/06

  Dry cells, i.e. cells wherein the electrolyte is rendered non-fluid · CPC title

• C22B7/006

  Wet processes · CPC title

• C22B47/00

  Obtaining manganese · CPC title

• H01M6/52 Primary

  Reclaiming serviceable parts of waste cells or batteries {, e.g. recycling} · CPC title

• H01M4/42

  Alloys based on zinc · CPC title