Systems and methods for direct recycling and upcycling of spent cathode materials using Flame-Assisted Spray Pyrolysis Technology (FAST). In illustrative embodiments, cathode layers are separated and collected from spent battery cells. The cathode laminate is ground to a powdered form and treated to remove contaminants by sifting into a hot stream of air which heats the powders, burning off contaminants. After cooling and particle collection, the powders may be dispersed into leaching solution to dissolve metal oxides and create an acid metal solution or ground into nano-sized primary particles and mixed with dispersing liquids to form a solution. The solution may be mixed with glycerol and additional metal salts to create a final precursor solution, which may undergo spray pyrolysis followed by drying and calcination to create cathode materials with high consistency and repeatability, or mixed with an alkaline metal salt solution and undergo electrodeposition to recover desired metal salts.

Methods of enhancing recovery of value sulfide and/or precious metal-bearing minerals from an ore containing such minerals as well as Mg-silicate, slime forming minerals, and/or clay by adding a froth phase modifier agent to the ore, and subjecting the ore to a froth flotation process performed under acidic conditions, are provided herein.

The present disclosure refers to a method of obtaining metal ions from a battery, the method comprising adding a crushed battery to a leaching solution comprising fruit and an ammonium salt, thereby obtaining a leachate comprising metal ions.

Certain method embodiments are described and useful for recycling permanent magnet materials (e.g. permanent magnet alloys) and battery materials (e.g. battery electrode materials) to extract critical and/or valuable elements including REEs, Co and Ni. Method embodiments involve reacting such material with at least one of an ammonium salt and an iron (III) salt to achieve at least one of a liquid phase chemical reaction and a mechanochemical reaction.

A process for recovery of one or more target metals, selected from precious metals and chalcophile metals as respectively herein defined, from materials containing precious and/or chalcophile metal/s, said process including: (i) leaching the metal containing material with an aqueous solution containing: a metal liberator comprising an amino acid; and a metal retainer comprising one or more of ammonia, ammonium salts, carboxylic acids, carboxylic acid salts, dicarboxylic acids, dicarboxylic acid salts, hydroxy-carboxylic acids, hydroxy-carboxylic acid salts, ethylene diamine tetra-acetic acid (EDTA) and EDTA salts, to produce a leachate containing the target metal/s; and (ii) extracting the metal from the leachate.

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.

Disclosed in the present invention is a method for extracting valuable metal from low-matte nickel converter slag. The method comprises: mixing low-matte nickel converter slag and quicklime then calcinating, obtaining a calcinated material; grinding and magnetically separating the calcinated material, obtaining silicate and iron-rich slag; adding a strong alkali solution to the iron-rich slag to perform leaching processing, and performing solid-liquid separation, obtaining a filtrate and a residue; mixing the residue with an acid solution, performing oxygen pressure acid leaching, and performing solid-liquid separation, obtaining a leachate and iron oxide; introducing hydrogen sulfide gas into the leachate, adjusting the pH, and performing solid-liquid separation, obtaining a copper sulfide precipitate and a nickel-cobalt-containing filtrate. In the present invention, first, removing silicon dioxide is removed by means of calcination to prepare silicate, then iron oxide is prepared by means of acid leaching, and finally metal separation is performed on the leachate, causing various components of the converter slag to be effectively utilized. The process flow of the present invention is short and effectively utilizes each component of the low-matte nickel converter slag, waste is turned into valuable material, and the loss of valuable metal elements is reduced.

A method of recovering cobalt and nickel includes the steps of: adding alkaline to an acidic solution containing aluminum together with cobalt and nickel, adjusting pH of the acidic solution to 5 to 7, and converting the cobalt, the nickel and the aluminum into hydroxides thereof; recovering the hydroxides by solid-liquid separation, mixing the recovered hydroxides with an alkaline solution, and leaching aluminum contained in the hydroxides under a liquid condition of pH 8 or more; and recovering a cobalt hydroxide and a nickel hydroxide that aluminum is separated therefrom by solid-separation on a leachate.

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).