Nickel Cathode Leaching Under Pressure for Battery-Grade Sulfate

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Solution Overview

Problem

The existing methods for producing nickel sulfate solutions for secondary batteries, which involve leaching nickel under atmospheric pressure with oxygen or ozone as oxidizing agents, suffer from low leaching efficiency.

Innovation Solution

A method involving a leaching step in sulfuric acid under high temperature and high pressure, with the option to add oxygen or nitrogen gas, followed by neutralization and filtration, to enhance nickel sulfate solution production efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If oxygen gas or ozone is added as an oxidizing agent under atmospheric pressure condition, then the leaching process can be performed, but the leaching efficiency is lowered

Engineering Contradiction:

Improveleaching efficiencyVSAvoidpressure condition

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The patent changes the pressure parameter from atmospheric pressure to high pressure (autoclave conditions) and adjusts temperature accordingly (100-200°C). This parameter change enables significantly improved leaching efficiency while maintaining safe operational conditions through proper pressure management

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs nitrogen gas as an inert atmosphere to cushion and control the high-pressure leaching environment. This prevents uncontrolled reactions and ensures safe operation during high-pressure processing, allowing the system to achieve high leaching efficiency without safety compromises

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If high temperature and high pressure are applied during leaching, then leaching efficiency is enhanced, but operational safety concerns may arise

Engineering Contradiction:

Improveleaching efficiencyVSAvoidoperational safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent uses nitrogen gas to create an inert atmosphere during high-temperature and high-pressure leaching. This inert environment prevents uncontrolled oxidation reactions and ensures operational safety while maintaining the high efficiency benefits of elevated temperature and pressure conditions

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The nitrogen gas atmosphere serves as a cushioning medium that controls and stabilizes the high-pressure environment before any potential uncontrolled reactions can occur. This pre-established inert environment ensures that even under high temperature and pressure, the process remains safe and controllable

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method significantly improves leaching efficiency and safety by operating under high temperature and pressure conditions, achieving higher nickel concentrations and safer operations compared to traditional methods.

Implementation Method 1

a leaching step of leaching a nickel cathode in sulfuric acid under a high temperature and a high pressure to produce a leachate

Methodology Applied

Scientific EffectLeaching: Solvation

Implementation Method 2

when a nickel sulfate solution is produced by leaching a raw material containing nickel in such a method that oxygen gas or ozone is added as an oxidizing agent

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 3

nitrogen gas may be added in the leaching step

Methodology Applied

Scientific EffectInert atmosphere:

Implementation Method 4

a neutralization step of neutralizing the leachate produced in the leaching step to produce a neutralized solution

Methodology Applied

Scientific EffectNeutralization:

Implementation Method 5

a filtration step of filtering the neutralized solution produced in the neutralization step to produce a filtrate

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS12258282B2Method for producing nickel sulfate solution for secondary battery from nickel cathode

Publication Date: 2025.03.25 KOREA ZINC CO LTD

AI summary

A method for producing a nickel sulfate solution includes a leaching step of leaching a nickel cathode in sulfuric acid under a high temperature and a high pressure to produce a leachate, a neutralization step of neutralizing the leachate produced in the leaching step to produce a neutralized solution, and a filtration step of filtering the neutralized solution produced in the neutralization step to produce a filtrate.