Hydrometallurgical Recovery of Metals from Spent Lithium-Ion Batteries with Ionic Liquids and Deep Eutectic Solvents

This work describes the continuous separation of cobalt and nickel by solvent extraction in a numbered-up millifluidic system (1 mm ID) using Cyphos IL 101 (C101) as extractant, which is recycled. A dilution of 50 vol% C101 in p-cymene was chosen as the optimal trade-off between extraction performance and hydrodynamic properties of the solvent. The effects of channel length (20–100 cm), flow rate (1–2.5 mL min−1) and temperature (20–70 °C) were investigated on the extraction, scrubbing and stripping performance in a single-channel system. Subsequently, the developed manifold structure (five parallel reactors) was benchmarked against the single-channel system, which displayed a maldistribution of only 1% and performed equally well as the single-channel system. Then, a continuous separation process of one extraction and two countercurrent stripping stages was executed for 6 h with the proven manifold. A cobalt and nickel purity of, respectively, 99.7 and 97.7 % were achieved at a rate of 5 mL min−1. Stable slug flow was observed in the entire system throughout the operating period. 

Cobalt/nickel purification by solvent extraction with ionic liquids in millifluidic reactors: From single-channel to numbered-up configuration with solvent recycle

Enhancing the efficiency of separation in high-viscosity biphasic liquid purification processes can significantly reduce energy consumption and costs. This study has developed a co-axial biphasic liquid separator that can continuously and instantaneously separate two-phase mixtures with viscosities up to 2000 mPa∙s at room temperature, to meet real industrial needs. This co-axial biphasic liquid separator uses a special helix wire structure that separates the two-phase fluids based on the difference in surface tension, unaffected by the viscosity of the liquids. In experiments with PMMA-toluene-water mixtures, the flow rate can reach up to 4000 μl/min, with PMMA recovery rates consistently above 83.6 %, and as high as 91.5 %. In experiments with undiluted heavy oil–water, a purity of up to 87.58 % was achieved for heavy oil, and for diluted heavy oil, the purity even reached as high as 92.15 %. The separator demonstrated remarkable universality and durability, maintaining stable and high-purity biphasic separation across varying flow rates, through 15 cycles of repeated use, and during prolonged operations of up to one hour, without any system failures. The co-axial biphasic liquid separator developed in this study is currently the only few microseparator in continuous processes capable of separating liquids with viscosities over 2100 mPa∙s, and it could decrease the cost of relevant process development in industrial setups, realizing the vision of green manufacturing. 

Continuous high viscosity biphasic liquid separation

Flow-based recovery of acetic acid from aqueous solutions using bio-derived terpenes as extracting solvents

Non-aqueous solvent extraction of cobalt and nickel using undiluted ionic liquids in milliflow contacting devices

Effect of dilution on the performance of ionic liquids in milliflow solvent extraction applications: Towards integration of extraction, scrubbing and stripping operations with in-line membrane-based phase separation

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Effect of dilution on the performance of ionic liquids in milliflow solvent extraction applications: Towards integration of extraction, scrubbing and stripping operations with in-line membrane-based phase separation

Cobalt/nickel purification by solvent extraction with ionic liquids in millifluidic reactors: From single-channel to numbered-up configuration with solvent recycle