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Slags generated from pyrometallurgical processing of spent Li-ion batteries are reservoirs of Li compounds that, on recycling, can reintegrate Li into the material stream. In this context, γ-LiAlO2 is a promising candidate that potentially increases recycling efficiency due to its high Li content and favorable morphology for separation. However, its solidification kinetics depends on melt compositions and cooling strategies. The Engineered Artificial Minerals approach aims to optimize process conditions that maximize the desired solid phases. To realize this goal, understanding the coupled influence of external cooling kinetics and internal kinetics of solid/liquid interface migration and mass and thermal diffusion on solidification is critical. In this work, the solidification of γ-LiAlO2 from a Li2O-Al2O3 melt is computationally investigated by applying a non-equilibrium thermodynamic model to understand the influence of varying processing conditions on crystallization kinetics. A strategy is illustrated that allows the effective utilization of thermodynamic information obtained by the CALPHAD approach and molecular dynamics-generated diffusion coefficients to simulate kinetic-dependent solidification. Model calculations revealed that melts with compositions close to γ-LiAlO2 remain comparatively unaffected by the external heat extraction strategies due to rapid internal kinetic processes. Kinetic limitations, especially diffusion, become significant for high cooling rates as the melt composition deviates from the stoichiometric compound.

The pyridinium phenolate punicine is a switchable molecule from Punica granatum. Depending on the pH, punicine exists as a cation, neutral molecule, anion, or dianion. In addition, punicine reacts to light, under the influence of which it forms radical species. We report on three punicine derivatives that possess an adamantyl, 2-methylnonyl, or heptadecyl substituent and on their performance in the flotation of lithium aluminate, an engineered artificial mineral (EnAM) for the recycling of lithium, e.g., from lithium-ion batteries. By optimizing the parameters: pH and light conditions (daylight, darkness), recovery rates of 92% of LiAlO2 are achieved. In all cases, the flotation of the gangue material gehlenite (Ca2Al[AlSiO7]) is suppressed. IR, the contact angle, zeta potential measurements, TG-MS, and PXRD confirm that the punicines interact with the surface of LiAlO2, which is covered by LiAl2(OH)7 after contact to water, resulting in a hydrophobization of the particle. The plasma pretreatment of the lithium aluminate has a significant influence on the flotation results and increases the recovery rates of lithium aluminate in blank tests by 58%. The oxidative plasma leads to a partial dehydratisation of the LiAl2(OH)7 and thus to a hydrophobization of the particles, while a reductive plasma causes a more hydrophilic particle surface.

Due to the increasing demand for electromobility, the recovery of technologically relevant elements from spent Li-ion batteries is becoming increasingly important. Pyrometallurgical processing can deal with a broad range of input materials. Unfortunately, ignoble elements such as Li and Mn enter the slag. A novel approach to facilitate this processing is the Engineered Artificial Minerals (EnAM) strategy for the recovery of critical elements. The aim of this study is to investigate whether it is possible to stabilize Li in Li-manganates as the first crystallizate. For this purpose, synthetic oxide slags (Li, Mg, Al, Si, Ca, Mn) of varying compositions were made. The constituting compounds were identified using inductively coupled plasma optical emission spectrometry, powder X-ray diffraction, X-ray absorption near-edge structure analysis, and electron probe microanalysis. These results provide an understanding of the solidification process and the behavior of the elements of concern. Lithium-manganate(III) (LiMnO2) crystallized first, next to hausmannite (Mn2+Mn3+2O4) in a matrix consisting of wollastonite (CaSiO3) and larnite (Ca2SiO4). Within the structure of LiMnO2, Li and Mn can replace each other in certain proportions. By adding Al and Mg spinel, solid solutions between Mn2+Mn3+2O4, MnAl2O4, MgAl2O4 and LiMnO2 are expected and described by the stoichiometry formula: (Li(2x),Mg(1x),Mn(2+(1–x)))1+x(Al(2–z),Mn3+(z))2O4.

Basic oxygen furnace (BOF) slag accounts for the majority of all residual materials produced during steelmaking and may typically contain certain transition metals. Vanadium, in particular, came into focus in recent years because of its potential environmental toxicity as well as its economic value. This study addresses the vanadium chemistry in BOF slags to better understand its recovery and save handling of the waste stream. The experimental results from the electron probe microanalysis (EPMA) study show that vanadium is preferably incorporated in calcium orthosilicate-like compounds (COS), with two variations occurring, a low vanadium COS (COS-Si) (approx. 1 wt.%), and a high vanadium COS (COS-V) (up to 18 wt.%). Additionally, vanadium is incorporated in dicalcium ferrite-like compounds (DFS) with an average amount of 3 wt.%. Using powder x-ray diffraction analysis (PXRD), EPMA, and virtual component models, stoichiometric formulas of the main vanadium-bearing phases were postulated. The stoichiometries give an estimate of the oxidation states of vanadium in the respective hosts. According to these results, trivalent vanadium is incorporated on the Fe-position in dicalcium ferrite solid solution (DFS), and V4+ and V5+ are incorporated on the Si-position of the COS.

The recovery of technically important elements like lithium from slag of pyrometallurgical recycling of lithium traction batteries will be very important in future due to the expected increasing demand of this element with the upcoming world-wide implementation of electro mobility. Therefore, the investigation of possibilities to recover lithium from pyrometallurgical slag from the recycling of lithium traction batteries is mandatory. In this context, the EnAM (engineered artificial mineral) approach is very promising. Solidified melt of synthetic recycling slag with the compounds Li2O-MgO-Al2O3-SiO2-CaO-MnO contains various Li-bearing phases including spinel solid solution, Li-aluminate and eucryptite-like Li-alumosilicate. Most probably, the Ca-alumosilicate matrix (melilite-like solid solution) incorporates lithium as well. These compounds can be determined and calculated to an acceptable approximation with electron probe microanalysis (EPMA). Nevertheless, an adequate precise measurement of lithium is virtually impossible due to the extremely low fluorescence yield and long wavelength of Li Kα. Secondary mass spectrometry (SIMS) can be used to fill this gap in the analytical assessment of the slag. Therefore, the combination of these two analytical methods can distinctively improve the mineralogical and chemical characterization of lithium-containing solidified (slag) melt.

Lithium aluminum oxide has previously been identified to be a suitable compound to recover lithium (Li) from Li-ion battery recycling slags. Its formation is hampered in the presence of high concentrations of manganese (9 wt.% MnO2). In this study, mock-up slags of the system Li2O-CaO-SiO2-Al2O3-MgO-MnOx with up to 17 mol% MnO2-content were prepared. The manganese (Mn)-bearing phases were characterized with inductively coupled plasma optical emission spectrometry (ICP-OES), X-ray diffraction (XRD), electron probe microanalysis (EPMA), and X-ray absorption near edge structure analysis (XANES). The XRD results confirm the decrease of LiAlO2 phases from Mn-poor slags (7 mol% MnO2) to Mn-rich slags (17 mol% MnO2). The Mn-rich grains are predominantly present as idiomorphic and relatively large (>50 µm) crystals. XRD, EPMA and XANES suggest that manganese is present in the form of a spinel solid solution. The absence of light elements besides Li and O allowed to estimate the Li content in the Mn-rich grain, and to determine a generic stoichiometry of the spinel solid solution, i.e., (Li(2x)Mn2+(1−x))1+x(Al(2−z),Mn3+z)O4. The coefficients x and z were determined at several locations of the grain. It is shown that the aluminum concentration decreases, while the manganese concentration increases from the start (x: 0.27; z: 0.54) to the end (x: 0.34; z: 1.55) of the crystallization.

The recovery of critical elements in recycling processes of complex high-tech products is often limited when applying only mechanical separation methods. A possible route is the pyrometallurgical processing that allows transferring of important critical elements into an alloy melt. Chemical rather ignoble elements will report in slag or dust. Valuable ignoble elements such as lithium should be recovered out of that material stream. A novel approach to accomplish this is enrichment in engineered artificial minerals (EnAM). An application with a high potential for resource efficient solutions is the pyrometallurgical processing of Li ion batteries. Starting from comparatively simple slag compositions such as the Li-Al-Si-Ca-O system, the next level of complexity is reached when adding Mg, derived from slag builders or other sources. Every additional component will change the distribution of Li between the compounds generated in the slag. Investigations with powder X-Ray diffraction (PXRD) and electron probe microanalysis (EPMA) of solidified melt of the five-compound system Li2O-MgO-Al2O3- SiO2-CaO reveal that Li can occur in various compounds from beginning to the end of the crystallization. Among these compounds are Li1−x(Al1−xSix)O2, Li1−xMgy(Al)(Al3/2y+xSi2−x−3/2y)O6, solid solutions of Mg1−(3/2y)Al2+yO4/LiAl5O8 and Ca-alumosilicate (melilite). There are indications of segregation processes of Al-rich and Si(Ca)-rich melts. The experimental results were compared with solidification curves via thermodynamic calculations of the systems MgO-Al2O3 and Li2O-SiO2-Al2O3.

Rare earth-bearing gypsum tailings from the fertilizer industry are a potential source for an economically viable and sustainable production of rare earth elements. Large quantities are generated inter alia in Catalão, Brazil, as a by-product in a fertilizer production plant. Hitherto, the gypsum has been used as soil conditioner in agriculture or was dumped. The cooperative project, “Catalão Monazite: Economical exploitation of rare earth elements from monazite-bearing secondary raw materials,” intends to extract rare earth elements from these gypsum tailings. In this paper, a chemical process route to obtain a mixed rare earth carbonate from a monazite concentrate, was investigated. The results of the digestion, leaching, and precipitation experiments are presented and discussed herein. This includes reagent choice, process parameter optimization through experimental design, mineralogical characterization of the feed material and residues, purification of the leach solution, and precipitation of the rare earth as carbonates. The results showed that a rare earth extraction of about 90% without the mobilization of key impurities is possible during a sulfuric acid digestion with two heating stages and subsequent leaching with water. In the following purification step, the remaining impurities were precipitated with ammonium solution and the rare earth elements were successfully recovered as carbonates with a mixture of ammonium solution and ammonium bicarbonate.