Lead from lead acid battery scrap is recovered in two separate production streams as clean grid lead and as high-purity lead without smelting. In preferred aspects, lead recovery is performed in a continuous process that uses an aqueous electroprocessing solvent and electro-refining and spent electroprocessing solvent can be recycled to the recovery process.

An electrorefining process for refining relatively purer lithium metal from a lithium-alloy feedstock material using a three-layer electrorefining apparatus can include a) providing an anode layer comprising a molten, lithium-alloy feedstock material that includes a combination of lithium metal having a first purity and a carrier material; b) providing an electrolyte layer comprising a molten salt electrolyte material; c) providing a product layer comprising molten lithium metal having a second purity that is greater than the first purity above the electrolyte layer; and d) applying an activation electric potential that is sufficient to electrolyze the lithium-alloy feedstock material between an anode layer and the product layer that is electrically isolated from the anode layer, whereby lithium metal is liberated from the lithium-alloy feedstock material, migrates through the electrolyte layer and collects in the product layer.

Cerium oxide nanoparticles and methods of fabricating the same are provided. The cerium oxide nanoparticles may be fabricated by a method that may include injecting metal ions into cerium oxide particles and then removing (e.g., desorbing) at least some of the injected metal ions from the cerium oxide particles.

The present invention concerns a process for the recovery of lead from a lead pastel electrolytically, where the pastel contains lead sulfate. The process provides for the leaching of the non-desulfurised pastel and the subsequent removal of the sulfates by precipitation; the leachate containing the lead ions is then subjected to electrolysis for the recovery of metal lead. The present invention further relates to a process for the recovery of lead accumulator components, wherein the lead contained in the pastel of the accumulators is recovered according to the aforesaid process.

An apparatus for use in the electro-production of metals, comprising a plurality of anodes and a plurality of cathodes in an interleaved configuration, wherein each anode and cathode pair forms a cell; a plurality of power supplies, each cell associated with one or more respective power supplies; and the power supplies are arranged to control a direct current in the one or more cells to a predetermined value.

An apparatus for use in the electro-production of metals, comprising a plurality of anodes and a plurality of cathodes in an interleaved configuration, wherein each anode and cathode pair forms a cell; a plurality of power supplies, each cell associated with one or more respective power supplies; and the power supplies are arranged to control a direct current in the one or more cells to a predetermined value.

In one embodiment, the disclosed subject matter relates to an electrolytic cell that has: a cell reservoir; a cathode support retained on a bottom of the cell reservoir, wherein the cathode support contacts at least one of: a metal pad and a molten electrolyte bath within the cell reservoir, wherein the cathode support includes: a body having a support bottom, which is configured to be in communication with the bottom of the electrolysis cell; and a support top, opposite the support bottom, having a cathode attachment area configured to retain a at least one cathode plate therein.

A method for extracting and separating rare earth elements comprising providing a rare earth-containing ore or tailings, grinding the rare earth-containing ore to form powdered ore; leaching the powered ore with at least one mineral acid, forming a leach solution comprising at least one metal ion, rare earth elements and a solid material, separating the solid material from the leach solution to form aqueous-metal concentrate, precipitating the aqueous-metal concentrate to selectively remove the metal ion from the leach solution and obtain a precipitate of the rare earth elements; heating the precipitate of the rare earth elements in air to form oxide of the rare earth elements, mixing the oxide of the rare earth elements with an ammonium salt and heating in a dry air/nitrogen, forming a mixture of anhydrous rare earth salts in an aqueous solution, and separating the rare earth elements from the aqueous solution by means of an electrowinning process.

A smart electrochemical processing apparatus includes a reaction container, an electrode unit and a surface feature scanner. The reaction container has an electrolytic tank. The electrode unit has a first electrode fixed to the electrolytic tank and a second electrode rotatably positioned at the electrolytic tank. The surface feature scanner is positioned at the electrolytic tank. Before being put in the electrolytic tank for processing, a workpiece positioned at the second electrode is scanned with the surface feature scanner while being rotated by the second electrode. After surface feature data of the workpiece have been collected, various process parameters can be adjusted to thereby achieve satisfactory surface treatment of the workpiece.

Systems and methods for recovering cobalt and other valuable metals from cobalt permanent magnets of various compositions, such as samarium cobalt magnets, are presented herein. In one embodiment, a method includes converting the permanent magnet material to a higher surface area form, such as a powder. The method also includes treating the converted permanent magnet material with an aqueous solution of ammonium carbonate to form a mixture (e.g., a slurry) that includes dissolved cobalt. In some embodiments, the method includes exposing the mixture to an oxidant to oxidize metallic constituents and form soluble species. The method also includes filtering the mixture to yield a filtrate and electroplating the cobalt onto a cathode from the filtrate.