The present disclosure provides methods and systems for recovering metals from lithium-ion batteries, and specifically to methods and systems for recovering cobalt and nickel jointly in metallic form via electrowinning processes. The present disclosure further provides methods and systems for preparing lithium-ion battery materials for use in metal recovery processes.

A copper/molybdenum separation processor is provided featuring a slurry/media mixture stage configured to receive a conditioned pulp containing hydrophobic molybdenite and hydrophilic copper, iron and other minerals that is conditioned with sodium hydrosulfide together with an engineered polymeric hydrophobic media, and provide a slurry/media mixture; and a slurry/media separation stage configured to receive the slurry/media mixture, and provide a slurry product having a copper concentrate and a polymerized hydrophobic media product having a molybdenum concentrate that are separately directed for further processing. The slurry/media mixture stage include a molybdenum loading stage configured to contact the conditioned pulp with the engineered polymeric hydrophobic media in an agitated reaction chamber, and load the hydrophobic molybdenite on the engineered polymeric hydrophobic media.

Provided is a recovery method for a copper-indium-gallium-selenium material, mainly comprising the steps of sulfuric acid aeration leaching at a high temperature, reducing selenium with sodium sulfite, separating copper by extracting, separating indium and gallium with an alkali, replacing indium, electrolyzing gallium, etc. In the recovery method for a copper-indium-gallium-selenium material, a sulfuric acid aeration leaching means is used, thus reducing acid gas pollution; at the same time, an extraction agent for copper is used to extract copper, wherein the separating effect is good and the cost is low, and the extracted copper is directly electrolyzed so as to obtain a high-purity metal copper; moreover, an alkali is used to separate gallium, wherein realizing the separation of indium and gallium only requires the adjustment of the pH value of a solution, the separating effect is good and the obtained indium and gallium products have a relatively high purity.

A method of recovering a metal from a low-grade ore which is subjected to cyanide leaching to produce a PLS which contains a metal cyanide which is removed from the PLS by ultrafiltration and nano-filtration, and then acidified and sulphidised to produce a metal sulphide from which the metal is extracted, and hydrogen cyanide which is recycled to the cyanide leaching step.

A method of controlling iron in a hydrometallurgical process is disclosed. The method may comprise the steps of: leaching (14, 114) a feed slurry (2, 102); forming a pregnant leach solution (12a, 12b; 112a, 112b); removing a first leach residue (18, 118) from the pregnant leach solution (12a, 12b); and sending a portion (12b, 112b) of the pregnant leach solution (12a, 12b) and/or raffinate (22, 122) produced therefrom, to an iron removal process (34, 134). According to some preferred embodiments, the iron removal process (34, 134) may comprise the steps of: sequentially processing the pregnant leach solution (12a, 12b) and/or raffinate (22, 122) produced therefrom in a first reactor (R.sub.1) a second reactor (R.sub.2), and a third reactor (R.sub.3); maintaining a pH level of the first reactor (R.sub.1) above 4, by virtue of the addition of a first base; maintaining a pH level of the second (R.sub.2) and/or third (R.sub.3) reactors above 8.5, by virtue of a second base; and forming solids (46) comprising magnetite (68). The method may further comprise the steps of performing a solid liquid separation step (36) after the iron removal process (34, 134); and performing a magnetic separation step (64) to remove magnetite (68) from said solids comprising magnetite (68), without limitation. A system for performing the method is also disclosed.

Systems and methods for basic leaching are provided. In various embodiments, a method is provided comprising leaching a slurry comprising a copper bearing material and an ammonia leach medium, adding copper powder to the slurry, separating the slurry into a pregnant leach solution and solids, and performing a solvent extraction on the pregnant leach solution to produce an loaded aqueous stream.

A process for recovering non-ferrous metals from a solid matrix may include: (a) leaching the solid matrix with an aqueous-based solution containing chloride ions, ammonium ions, and Cu.sup.2+ ions, having a pH of 6.5-8.5, in a presence of oxygen, at a temperature of 100 C.-160 C. and a pressure of 150 kPa-800 kPa, so as to obtain an extraction solution comprising leached metals and solid leaching residue; (b) separating the solid leaching residue from the extraction solution; and/or (c) subjecting the extraction solution to at least one cementation so as to recover the leached metals in elemental state. The pH may be greater than or equal to 6.5 and less than or equal to 8.5. Temperature may be greater than or equal to 100 C. and less than or equal to 160 C. Pressure may be greater than or equal to 150 kPa and less than or equal to 800 kPa.

A copper concentrate such as chalcopyrite is contacted with an aqueous solution includes acids and a reducing agent, such as vanadium (II) ions, chromium (II) ions, or tungstozincic acid (H.sub.6ZnW.sub.12O.sub.40). The aqueous solution reduces the copper in the copper concentrate, which can then dissolve into the solution for recovery therefrom, or precipitate out of solution as copper compounds or elemental copper for recovery in as a solid phase product. The solid phase product can then be isolated, dissolved, and further electrowinned to recover a copper product from the copper concentrate. Oxidized reducing agent can be recovered in an electrochemical device with ferrous iron reactants. Hydrometallurgical routes to convert copper concentrates to copper are potentially less expensive and less polluting than current pyrometallurgical processing and an advantageous response to environmental and economic pressures for increased copper production.

A method for the recovery of metals from a feed stream (1) containing one or more value metals, the method comprising: (i) passing the feed stream (1) to an alkaline leach (20) to form a slurry (5) including a pregnant leach liquor of soluble metal salts and a solid residue; (ii) separating the pregnant leach liquor (8) and the solid residue (7) of step (i); (iii) passing the separated pregnant leach liquor (8) of step (ii) to a solvent extraction step (42), wherein a loaded extractant (9) containing copper and nickel, and a raffinate (19) containing cobalt and lithium, are produced; (iv) recovering cobalt (24) from the raffinate (19) of step (iii); and (v) recovering lithium (38), ammonia (28) and ammonium chloride (39) from the cobalt depleted liquor (21) of step (iv).

In producing a copper concentrate by flotation in which copper minerals are separated from arsenic minerals by using oxoacids of sulfur and oxidants, the arsenic in the copper concentrate is reduced by a simple method. In producing the copper concentrate by the flotation in which an arsenic-containing copper ore is a raw material, the oxoacids of sulfur and hydrogen peroxide as the oxidant are used together as additive reagents, and added in this order.