Integration of physical operations in the hydrometallurgical processing of spent Zn-MnO2 batteries

The recycling of spent Zn-MnO2 batteries by hydrometallurgy involves the leaching of material previously treated by physical processing to allow the liberation of electrode particles and the separation of unwanted scrap. The integration of these physical operations with leaching is therefore crucial for the optimization of the process, allowing achieving high recovery yields of zinc and manganese and minimizing reactants consumption and iron contamination. In this paper, several options involving physical processing and leaching with sulphuric acid are presented and discussed. After batteries shredding and disaggregation, the separation of steel scrap was performed by sieving or magnetic separation, and the remaining solids were treated by leaching. These options were compared, in terms of metals recovery and contamination, with the alternative of direct leaching of all the shredded fractions without physical treatment. The separation of the steel scrap by sieving or magnetic separation allowed the removal from the circuit of 37 or 49% of iron, respectively, with losses of 15 or 6% of zinc and 2 or 4% of manganese. Therefore more than 50% of iron remained in the process, which was attributed to the presence of iron oxides formed by the corrosion of the battery cases. In the leaching operation, zinc dissolution was very effective (yields above 97%) while manganese is strongly depended from the process option, being its leaching proportional to the presence of scrap (yields of 80%, 56% and 43%, respectively in direct leaching, sieving / leaching and magnetic separation / leaching). These results showed that iron plays an important role in the reductive leaching of manganese species (III or IV), and so the presence of steel scrap in leaching, besides disadvantages concerning solutions contamination, contributes positively for the leaching efficiency.