Successive Solvent Extraction for High-Purity Nickel Recovery
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Solution Overview
Problem
Conventional lithium-ion battery recycling methods fail to efficiently handle the extraction of nickel and other metals from diverse cathode materials, leading to impurity contamination and significant loss of valuable metals due to complex processes and equipment requirements.
Innovation Solution
A two-stage liquid-liquid extraction process using dialkylphosphinic acid and alkylcarboxylic acid extractants to selectively remove cobalt, manganese, and nickel salts from an aqueous leach solution, followed by regeneration of the extractants for reuse, and subsequent crystallization of nickel salts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional recycling methods are used to extract metals from cathode materials, then the extraction process can be performed, but impurity contamination occurs and valuable metals are lost due to process complexity
Solution Approach 1:
The extraction process is divided into distinct sequential stages: impurity removal stage, first extraction stage for cobalt and manganese, and second extraction stage for nickel. Each stage uses specific extractants and conditions optimized for removing particular metals, thereby achieving high purity nickel recovery without requiring overly complex equipment
Solution Approach 2:
The patent systematically extracts different metal impurities (cobalt, manganese, nickel) from the aqueous leach solution using selective liquid-liquid extraction with specific organic extractants. This targeted removal approach isolates nickel in high purity form while recovering other valuable metals separately, resolving the contradiction between purity and process complexity
2Productivity
If extensive equipment and complex processes are used for metal extraction, then complete metal recovery can be achieved, but the process becomes unnecessarily complex and equipment-intensive
Solution Approach 1:
The organic extractants used in this process serve multiple functions: they selectively extract specific metals from the aqueous solution, can be regenerated and reused, and enable both purification and recovery of valuable metals. This multi-functionality achieves complete metal recovery without requiring separate specialized equipment for each function
Solution Approach 2:
The patent implements extractant regeneration where the organic extractants, after extracting metals from the solution, are treated to recover the metals and regenerate the extractant for reuse. This approach maintains high productivity through complete metal recovery while simplifying the overall process by eliminating the need for disposable extractants and reducing waste treatment requirements
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
Achieves high recovery rates of nickel with minimal loss of other metals, reducing the need for extensive equipment and simplifying the recycling process, thereby increasing the availability of pure nickel salts for reuse.
Implementation Method 1
The cobalt and manganese salts are extracted from the first purified aqueous solution in a first liquid-liquid extraction step with a first organic extractant
Implementation Method 2
The nickel salt is removed from the aqueous raffinate solution in a second liquid-liquid extraction step using a second organic extractant
Implementation Method 3
an aqueous leach solution comprising cobalt, manganese, and nickel salts
Data Source
AI summary
Methods of recovering a nickel salt are disclosed. The method includes removing one or more impurities from an aqueous leach solution including cobalt, manganese, and nickel salts to produce a first purified aqueous solution including the cobalt, manganese, and nickel salts. The method includes extracting the cobalt and manganese salts from the first purified aqueous solution in a first liquid-liquid extraction step using a first organic extractant to produce an aqueous raffinate solution including the nickel salt and a first loaded organic solution including the cobalt and manganese salts. The method further includes extracting the nickel salt from the aqueous raffinate solution in a second liquid-liquid extraction step using a second organic extractant to produce a second loaded organic solution including the nickel salt. Systems for recovering a nickel salt are also disclosed.