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.

A removable electrode module for engagement with an electrolysis chamber comprises a first electrode, a second electrode, and a suspension structure. The suspension structure comprises a suspension rod coupled to the first electrode. The second electrode is suspended or supported by the suspension structure, which comprises at least one electrically-insulating spacer element for retaining the second electrode in spatial separation from the first electrode.

A removable electrode module for engagement with an electrolysis chamber comprises a first electrode, a second electrode, and a suspension structure. The suspension structure comprises a suspension rod coupled to the first electrode. The second electrode is suspended or supported by the suspension structure, which comprises at least one electrically-insulating spacer element for retaining the second electrode in spatial separation from the first electrode.

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. Spent electroprocessing solvent and/or base utilized to treat lead paste from the lead acid battery scrap can be recycled to the recovery process.

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. Spent electroprocessing solvent and/or base utilized to treat lead paste from the lead acid battery scrap can be recycled to the recovery process.

A molten salt, membrane electrolyzer apparatus may include an anolyte compartment containing a molten salt anolyte comprising primarily chloride salts and a lithium carbonate (Li.sub.2CO.sub.3) 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.

A crust breaker and ore feeder device for electrolytic aluminum smelting employs an in-line three-position pneumatic cylinder capable of moving the plunger shaft between a raised position and a fully lowered position. A dose meter in the form of a cylindrical member rests a small distance above the valve seat of the crust breaker. In the raised position the dose meter fits within the dosing cup and receives the dose of alumina. In the lowered position of the crust breaker, the dose meter slows down the flow of alumina into the electrolytic liquid, with the alumina flowing out through cutouts formed in the lower rim of the dose meter.

A crust breaker and ore feeder device for electrolytic aluminum smelting employs an in-line three-position pneumatic cylinder capable of moving the plunger shaft between a raised position and a fully lowered position. A dose meter in the form of a cylindrical member rests a small distance above the valve seat of the crust breaker. In the raised position the dose meter fits within the dosing cup and receives the dose of alumina. In the lowered position of the crust breaker, the dose meter slows down the flow of alumina into the electrolytic liquid, with the alumina flowing out through cutouts formed in the lower rim of the dose meter.

A metallurgical method for operating an autogenous production circuit for producing metal(s), said method using one or more oxidizing agents generated electrolytically in a cell with one or more interfaces which allows anion exchange; said method comprising steps of: (a) leaching of mineral(s) or material(s) containing at least one metal of interest (LX) in a first cell (A) to produce a pregnant leach solution (2) and an acid-ferrous aqueous solution (8); (b) using solvent extraction process(es) or selection process(es) in a second cell (B) to concentrate said metal(s) of interest (SX) of said pregnant leach solution (2) to produce a rich electrolyte (5) and a raffinate solution (4), said raffinate solution (4) being recycled in said first cell (A); and (c) electrowinning (EW) in a third cell (C) of said rich electrolyte (5) received from said second cell (B) and said acid-ferrous aqueous solution (8) received from said first cell (A), for producing a metal cathode (6) and an acid-ferric acid solution (9), said acid-ferric acid solution (9) being recycled in said first cell (A), wherein said steps (a), (b) and (c) are performed in said autogenous circuit that includes said first, second and third cells (A, B, C) with one or more anionic interfaces producing anodic and cathode reactions.

An anode assembly is provided having a pair of channels; anodes in slidable communication with the channels; conduit to direct carrier gas to the anode; and conduit to remove reaction gas from the anode. Also provided is a method for continuously feeding anodes into a electrolytic bath, the method having the steps of stacking the anodes such that all of the anodes reside in the same plane and wherein the stack includes a bottom anode; contacting the bottom anode with the electrolytic bath for a time and at a current sufficient to cause the bottom anode to be consumed during an electrolytic process; using gravity to replace the bottom anode with other anodes defining the stack.