Processes for recycling spent catalysts, recycling rechargeable batteries, and integrated processes thereof
AssigneeAleon Renewable Metals, LLC.
InventorsAlfred Salazar, Tarun K. Bhatt, Micki Kennedy
Life of this patent
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Abstract
Integrated recycling method and processes including recycling spent catalyst to produce one or more water-soluble metal salts and one or more water-insoluble tail byproducts, and recycling rechargeable batteries to produce one or more battery-grade metals and one or more pure metallic byproducts, wherein the water insoluble tail byproduct is a feedstock in recycling the rechargeable batteries, the impure metallic byproduct is a feedstock in recycling the spent catalyst, or both.
Claims14
An integrated recycling method comprising:
- recycling spent catalyst to produce one or more water-soluble metal salts and one or more water-insoluble tail byproducts;
- and
- recycling rechargeable batteries to produce one or more battery-grade metals and one or more impure metallic byproducts, wherein the water insoluble tail byproduct is a feedstock in recycling the rechargeable batteries, and the impure metallic byproduct is a feedstock in recycling the spent catalyst, or both.
An integrated recycling method comprising:
- recycling spent catalyst selected residue desulfurization catalyst (RDS), hydrodesulfurization catalyst (HDS), or both, to produce vanadium pentoxide, molybdenum trioxide, or both, and an alumina tail byproduct;
- and
- recycling rechargeable batteries to produce one or more battery-grade metals and one or more impure metallic byproducts, the one or more battery-grade metals selected from lithium carbonate, nickel sulfate, manganese sulfate, or cobalt sulfate, and the one or more impure metallic byproducts selected from impure vanadium or impure molybdenum, wherein the alumina tail byproduct is a feedstock in recycling the rechargeable batteries and the impure metallic byproduct is a feedstock in recycling the spent catalyst.
A spent catalyst recycling process comprising:
- pretreating a spent catalyst to form a pretreated spent catalyst;
- blending the pretreated spent catalyst with sodium carbonate to form a blend;
- calcining the blend to form a calcine including one or more water-soluble metals;
- leaching the calcine to form an overflow including a strong solution including the one or more water-soluble metals and an underflow including the one or more insoluble metallic tail byproducts;
- treating the strong solution with one or more precipitating agents to remove impurities to from a purified strong solution;
- and
- recovering one or more water-soluble metal oxides from the purified strong solution via a vanadium recovery circuit, a molybdenum recovery circuit, or both.
Dependencies are inferred from the claim text.