US 12,322,770 B2
Processes and systems for purifying independent streams of manganese, nickel, and cobalt from lithium-ion battery waste streams
Reza Katal, Parkville (AU); Ebrahim Akhondi, Yarraville (AU); Mahdi Ghorbani Mousaabadi, Hughesdale (AU); and Pavel Cherepanov, Armstrong Creek (AU)
Assigned to GREEN LI-ION PTE. LTD., Singapore (SG)
Filed by GREEN LI-ION PTE. LTD., Singapore (SG)
Filed on Apr. 19, 2024, as Appl. No. 18/640,391.
Claims priority of provisional application 63/534,183, filed on Aug. 23, 2023.
Prior Publication US 2025/0070293 A1, Feb. 27, 2025
Int. Cl. H01M 10/54 (2006.01); C22B 3/00 (2006.01); C22B 3/30 (2006.01); C22B 3/44 (2006.01); C22B 7/00 (2006.01); C22B 47/00 (2006.01)
CPC H01M 10/54 (2013.01) [C22B 3/30 (2021.05); C22B 3/44 (2013.01); C22B 7/007 (2013.01); C22B 23/0484 (2013.01); C22B 47/00 (2013.01)] 27 Claims
OG exemplary drawing
 
1. A process for independently recovering manganese (Mn), cobalt (Co), and nickel (Ni) from a lithium-ion battery waste stream, the process comprising:
separating manganese (Mn) from a waste liquid stream originating from the lithium-ion battery waste stream comprising manganese (Mn), nickel (Ni), and cobalt (Co), the separating of manganese (Mn) comprising:
(i) introducing a first oxidant to the waste liquid stream to form solid manganese dioxide (MnO2);
(ii) reacting the waste liquid stream with ozone (O3) to form solid manganese dioxide (MnO2); or
(iii) both (i) and (ii); and
removing the solid manganese dioxide (MnO2) from the waste liquid stream; and
separating nickel (Ni) and cobalt (Co) from the waste liquid stream by:
(iv) adding sulfuric acid (H2SO4) and a second oxidant to the waste liquid stream, followed by adjusting pH to greater than or equal to about 4, adding sodium hypochlorite (NaClO) to form cobalt oxyhydroxide (COOH), passing the waste liquid stream through a filter to form a retentate comprising cobalt oxyhydroxide (COOH) and a filtrate comprising nickel (Ni) and liquid;
(v) recovering cobalt (Co) from the retentate by purifying the cobalt oxyhydroxide (COOH) in the retentate and adding sulfuric acid (H2SO4) and a third oxidant to the retentate followed by one or more of the following processes:
a. separating nickel (Ni) from cobalt (Co) by adjusting the pH of the retentate to be less than or equal to about 2.5 and passing the retentate into one or more chromatographic columns so that cobalt (Co) is retained within the one or more chromatographic columns, followed by a stripping process to recover cobalt (Co) from the one or more chromatographic columns;
b. removing liquid from the retentate to recover cobalt sulfate (CoSO4); and/or
c. adjusting pH of the retentate to greater than or equal to about 9 to precipitate a cobalt hydroxide product comprising one or more of cobalt hydroxide (Co(OH)2) or cobalt oxyhydroxide (COOH);
(vi) recovering nickel (Ni) from the filtrate by one of the following processes:
a. removing liquid from the filtrate to recover nickel sulfate (NiSO4); and/or
b. adjusting pH of the filtrate to greater than or equal to about 9 to precipitate nickel hydroxide (Ni(OH)2).