Abstract: A method of precipitating copper sulphide from an incoming feed stream comprising copper liberated from within battery materials can includes the steps of: a) receiving an incoming feed stream comprising copper entrained in a carrier liquid in a precipitation apparatus; b) introducing a sulphide reductant to the feed stream to precipitate copper sulphide solids out of the feed stream during a precipitation residence time that is less than 24 hours to produce a copper sulphide slurry; and processing the copper sulphide slurry to separate the precipitated copper sulphide solids and provide a copper-depleted stream.

Abstract: A method of processing a black mass material feed material can include a) receiving a black mass material feed material; b) acid leaching the black mass material at a pH that is less than 4, thereby producing a pregnant leach solution (PLS) comprising at least 80% the lithium from the black mass feed material, and at least a portion of the iron and the phosphorous from the black mass feed material; providing a first intermediary solution after completing step b); and separating at least 90% of the iron and the phosphorous from the first intermediary solution to provide an output solution.

Abstract: A molten salt, membrane electrolyzer apparatus may include an anolyte compartment containing a molten salt anolyte comprising primarily chloride salts and a lithium carbonate (Li2CO3) feed material. A first and second electrode assemblies each having respective anodes, cathode housings proximate the first anode within the anolyte compartment and in fluid contact with the molten salt anolyte and having a primary transfer portion comprising a porous membrane and cathodes positioned within the first catholyte compartment so that the primary transfer portion is disposed between respective anode and cathode. A power supply can be configured to apply an electric potential between the first anode and the first cathode that is sufficient to initiate electrolysis of lithium carbonate and is greater than the electric potential required to initiate LiCl electrolysis.

Abstract: A process for recovering materials from a black mass material obtained from lithium-ion batteries can include: i) conveying a black mass material as a black mass solid stream; ii) leaching the black mass solid stream to form a pregnant leach solution and residual solids; iii) separating the pregnant leach solution from the residual solids; iv) isolating a copper product from the pregnant leach solution; v) isolating an aluminum (Al) and/or iron (Fe) product from the pregnant leach solution; vi) isolating a manganese (Mn) product from the from the pregnant leach solution; vii) isolating a cobalt (Co) product from the from the pregnant leach solution; viii) isolating a nickel (Ni) product from the from the pregnant leach solution; ix) isolating a salt by-product from the pregnant leach solution; and x) isolating a lithium product the pregnant leach solution.

Abstract: An apparatus for carrying out size reduction of battery materials under immersion conditions can include a housing configured to hold an immersion liquid comprising at least one of sodium hydroxide and calcium hydroxide. A first feed chute may define an opening therein for receiving battery materials of a first type into the housing and a first submergible comminuting device may be disposed within the housing and submerged in the immersion liquid to receive the battery materials of the first type from the first feed chute. The first submergible comminuting device may be configured to cause a size reduction of the battery materials of the first type to form a first reduced-size battery material.

Abstract: An apparatus for carrying out size reduction of battery materials under immersion conditions can include a housing configured to hold an immersion liquid comprising at least one of sodium hydroxide and calcium hydroxide. A first feed chute may define an opening therein for receiving battery materials of a first type into the housing and a first submergible comminuting device may be disposed within the housing and submerged in the immersion liquid to receive the battery materials of the first type from the first feed chute. The first submergible comminuting device may be configured to cause a size reduction of the battery materials of the first type to form a first reduced-size battery material.

Abstract: The present application provides a process to recover materials from rechargeable lithium-ion batteries, thus recycling them. The process involves processing the batteries into a size-reduced feed stream; and then, via a series of separation, isolation, and/or leaching steps, allows for recovery of a copper product, cobalt, nickel, and/or manganese product, and a lithium product; and, optional recovery of a ferrous product, aluminum product, graphite product, etc. An apparatus and system for carrying out size reduction of batteries under immersion conditions is also provided.

Abstract: A process for recovering component materials from lithium battery materials, the process comprising the steps of: a) processing lithium battery materials in a comminuting apparatus comprising at least a first comminuting device that is submerged in an immersion liquid, thereby creating reduced-size battery materials and liberating electrolyte material and a black mass material comprising anode and cathode powders from within the lithium battery materials and providing a sized-reduced feed stream comprising the reduced size battery materials and the black mass material and electrolyte materials entrained within the immersion liquid; and b) processing the size-reduced feed stream to obtain at least a black mass solid stream that comprises the black mass material and a retained portion of the immersion liquid having entrained electrolyte materials.

Abstract: An apparatus for carrying out size reduction of battery materials under immersion conditions can include a housing configured to hold an immersion liquid comprising at least one of sodium hydroxide and calcium hydroxide. A first feed chute may define an opening therein for receiving battery materials of a first type into the housing and a first submergible comminuting device may be disposed within the housing and submerged in the immersion liquid to receive the battery materials of the first type from the first feed chute. The first submergible comminuting device may be configured to cause a size reduction of the battery materials of the first type to form a first reduced-size battery material.

Abstract: An apparatus for carrying out size reduction of battery materials under immersion conditions can include a housing configured to hold an immersion liquid comprising at least one of sodium hydroxide and calcium hydroxide. A first feed chute may define an opening therein for receiving battery materials of a first type into the housing and a first submergible comminuting device may be disposed within the housing and submerged in the immersion liquid to receive the battery materials of the first type from the first feed chute. The first submergible comminuting device may be configured to cause a size reduction of the battery materials of the first type to form a first reduced-size battery material.

Abstract: An apparatus for carrying out size reduction of battery materials under immersion conditions having a battery inlet and at least a first comminuting device disposed within a housing and configured to cause a size reduction of the battery materials to form reduced-size battery materials and to liberate electrolyte materials and a black mass material comprising anode and cathode powders from within the battery materials. An immersion liquid can be within the housing and can submerge the first comminuting device so the black mass material and the reduced-size battery material are entrained within the immersion liquid to form a sized-reduced feed stream. A feed outlet may be downstream from the first comminuting device.

Abstract: A process for recovering component materials from lithium battery materials, the process comprising the steps of: a) processing lithium battery materials in a comminuting apparatus comprising at least a first comminuting device that is submerged in an immersion liquid, thereby creating reduced-size battery materials and liberating electrolyte material and a black mass material comprising anode and cathode powders from within the lithium battery materials and providing a sized-reduced feed stream comprising the reduced size battery materials and the black mass material and electrolyte materials entrained within the immersion liquid; and b) processing the size-reduced feed stream to obtain at least a black mass solid stream that comprises the black mass material and a retained portion of the immersion liquid having entrained electrolyte materials.

Abstract: An apparatus for carrying out size reduction of battery materials under immersion conditions having a battery inlet and at least a first comminuting device disposed within a housing and configured to cause a size reduction of the battery materials to form reduced-size battery materials and to liberate electrolyte materials and a black mass material comprising anode and cathode powders from within the battery materials. An immersion liquid can be within the housing and can submerge the first comminuting device so the black mass material and the reduced-size battery material are entrained within the immersion liquid to form a sized-reduced feed stream. A feed outlet may be downstream from the first comminuting device.

Abstract: The present application provides a process to recover materials from rechargeable lithium-ion batteries, thus recycling them. The process involves processing the batteries into a size-reduced feed stream; and then, via a series of separation, isolation, and/or leaching steps, allows for recovery of a copper product, cobalt, nickel, and/or manganese product, and a lithium product; and, optional recovery of a ferrous product, aluminum product, graphite product, etc An apparatus and system for carrying out size reduction of batteries under immersion conditions is also provided.

Abstract: Provided is an acid mist control apparatus for the control of acid mist emissions in an electrolytic cell. The apparatus includes an elongate hood having longitudinal edges, an upper surface and a lower surface; and a receiving aperture which is adapted to receive therethrough an anode of an electrolytic cell.