Shrinking Core Model Research Articles

Leaching process assisted by cetyltrimethylammonium chloride for weathered crust elution-deposited rare earth ores: Leaching behavior, kinetic analysis and interfacial regulation

Magnesium salts are commonly employed as ammonium-free leaching agents in the extraction of weathered crust elution-deposited rare earth ores (WCE-REO). Nonetheless, these salts frequently face technical challenges, including relatively low leaching rates and inadequate permeability in the in-situ leaching process. In this study, cetyltrimethylammonium chloride (CTAC) was used as a novel leaching aid agent to improve the rare earth leaching process. The effects of CTAC and pH on the rare earth leaching behavior and permeability was investigated. The leaching kinetic model was established and the regulation mechanism by which CTAC interacts with clay mineral surfaces was revealed for rare earth leaching process enhanced by CTAC. The results indicate that the appropriate amount of CTAC can increase the permeation velocity by 1.16×10−4 cm·s−1. Moreover, the rare earth leaching rate increased from 83.75 % to 95.65 %, accompanied by a reduction in leaching equilibrium time under optimal conditions. However, a higher concentration of CTAC results in a lower permeation velocity due to the increasing viscosity and the hydrophilicity. The relatively low pH will affect permeability of composite leaching agent in the ore pillar, diminishing its beneficial impact on rare earth leaching. The kinetic equation, fitted by the shrinking core model, suggests that the leaching adheres to an internal diffusion control mechanism, underscoring mass transfer as the pivotal limiting factor in rare earth leaching. CTAC reduces surface tension and viscosity, facilitating the permeation of the leaching solution into the rare earth ore. Furthermore, CTAC can be adsorbed on the surface of rare earth mineral particles, increasing the contact angle of clay minerals, elevating the Zeta potential, and diminishing the thickness of the diffusion layer, thus promoting mass transfer during leaching. The results of atomic force microscopy (AFM) analysis shows that the appropriate amount of CTAC adsorbed on rare earth ores can decreases the thickness of the hydration film on the particles’ surface, further improving the mass transfer efficiency during the leaching process. The findings of this study offer new insights into the green and efficient extraction of rare earth resources from both theoretical and technical perspectives.

Kinetics and Mechanism of SiO2 Extraction from Acid-Leached Coal Gangue Residue by Alkaline Hydrothermal Treatment.

Acid-leached gangue residue is produced after the gangue extraction of metal ions; the main component is silicon, which can be used to extract silica. To ascertain the kinetics and mechanism of silica extraction from acid-leached coal gangue residue, this study explored the effects of the NaOH concentration, solid-to-liquid ratio, reaction temperature, and reaction time on the extraction process. The optimized conditions, determined through this investigation, involved a NaOH concentration of 4 mol/L, a reaction time of 4 h, a solid-to-liquid ratio of 1:4, and a reaction temperature of 180 °C, yielding a SiO2 extraction ratio of 90.16%. Additionally, the leaching kinetics of silica in a NaOH solution were examined using three kinetic equations from the "unreacted shrinking core model". The results revealed that the control type of the leaching process was the "mixing control", and the apparent activation energy was determined to be 52.36 kJ/mol.

Modeling copper leaching from non-pulverized printed circuit boards at high concentrations of bioregenerated ferric sulfate

This work studies the leaching of copper contained in waste printed circuit boards (PCB) with ferric sulfate, with the aim of improving the results found in the literature for an industrial application of the process. For this purpose, temperatures and concentrations of ferric ion higher than those of previous works (up to 60 °C and 40 g/L) are used. Furthermore, ferric sulfate can be continuously regenerated by ferro-oxidizing bacteria immobilized in a bioreactor, avoiding physical contact between waste and microorganisms to optimize independently operation conditions. A kinetic model was developed for the interpretation of the experimental results validated at different conditions. The model was based on a shrinking core model limited by mass transfer inside the PCB where the geometry and structure of the PCB has been considered and an excellent fit of the model to the experimental data was obtained. The connection with the bioreactor for biooxidation of the generated ferrous ion allows maintaining high concentrations of ferric when operating at high solid concentrations (5–10 %). In all the cases studied, more than 99 % of the copper contained in the non-pulverized PCB parts was dissolved in less than 24 h, with an average copper extraction rate of 0.6 g/L·h higher than those found in previous works.

Mechanism Analysis of the Reduction Process of the NiO-YSZ Anode of a Solid Oxide Fuel Cell by Hydrogen

Abstract Reduction of the nickel oxide-yttria stabilized zirconia (NiO-YSZ) anode is a significant step before the operation of a solid oxide fuel cell (SOFC). However, phenomena which occur during the reduction and their mechanism analyses are not summarized sufficiently. In this study, we investigated the influence of the hydrogen concentration, water vapor concentration of the reduction gas, Y2O3 content of the YSZ material of the anode, and temperature on the reduction process. The results showed that water vapor added to the hydrogen during reduction caused a temporary stasis period of the open circuit voltage. The length of the temporary stasis period was almost irrelevant to the water vapor concentration. During reduction, the length of the temporary stasis period of the open circuit voltage was negatively associated with hydrogen concentration and temperature, but positively associated with Y2O3 content of the YSZ material of the anode. After reduction, the SOFC showed better initial performance when the hydrogen concentration or the water vapor concentration during the reduction were higher. The classical shrinking core model can be used to explain these phenomena.

Kinetics analysis of copper extraction from copper smelting slag by sulfuric acid oxidation leaching

Copper smelting slag (CSS) is generally produced from the pyrometallurgy of copper sulfide concentrate, the current storage disposal methods of CSS not only occupy precious land and pollute the environment, but also waste resources. To recover copper from the CSS and explore the atmospheric pressure oxidative leaching kinetics of copper extraction from CSS with sulfuric acid was investigated intensively. In this study, the effect of particle size, sulfuric acid concentration, temperature, liquid-to-solid ratio, and hydrogen peroxide added amount were investigated comprehensively. The results indicated that the decrease of particle size and increase of other parameters can significantly promote the leaching of copper. Under the optimum conditions, 90.7 % of the copper in the CSS was effectively leached, other copper in the leaching slag mainly existed in the form of fine-grained embedded copper sulfide. The dominant phase of the leaching slag is magnetite, which could be further recovered by conventional magnetic separation. Moreover, the kinetics of copper atmospheric pressure oxidative leaching in CSS were further expounded. The results indicated that the copper leaching kinetic conforms to the shrinking core model, and the overall leaching reaction was controlled by the internal diffusion control with an activation energy of 11.22 KJ/mol. The apparent reaction order of sulfuric acid and particle size are determined to be 0.965 and 0.478 respectively. Finally, the kinetics model equation is established for copper at normal pressure as:1-23η-1-η2/3=0.032·CH2SO40.965·r0-0.956·t. This research could provide an alternative solution for the efficient utilization of CSS.

Catalytic coal gasification: mechanism, kinetics, and reactor model

Catalytic coal gasification is a promising technology in the field of clean coal utilization. A comprehensive understanding of mechanisms, reaction kinetic, and reactor model is crucial. This article summarizes and analyzes the catalytic mechanisms of key reactions, such as C–O2, C–CO2, C–H2O, and CO–H2. It also compares various kinetic models, including shrinking core model, random pore model, volume model and their respective modifications. Additionally, the article delves into mathematical modellings of catalytic coal gasification, encompassing molecular models or density functional theory, empirical model, computational fluid dynamics, Aspen modeling, and artificial neural network. The aim is to provide a roadmap for the development and scale up of reactors used in catalytic coal gasification.

Leaching phosphorous from the lime mud of kraft pulp mills: Towards sustainability

AbstractThe optimum conditions needed to separate phosphorus from the lime mud generated in kraft pulp mills were identified using different leaching solutions including carbonate, bicarbonate, and green liquor under variety of conditions. Carbonate ions seemed to be the active ion in the phosphorus leaching process. Bicarbonate solution seems to be the most effective leaching agent by removing 84% of phosphorus under the optimum operating conditions of 95°C, 2.92 m, and solution‐to‐ mud mass ratio of 3.6. The shrinking core model was used to determine the leaching mechanism and it showed that the leaching process is controlled by a mix of chemical reaction and diffusion through the particle. Two empirical models were developed to predict the leaching efficiency as a function of carbonate concentration and temperature. Counter‐current leaching was shown to be beneficial in increasing the leaching efficiency with the carbonate solutions.

Random pore model insights into structural and operational parameters for hydrogen-based iron oxide reduction

The hydrogen-based direct reduction of iron oxide (DRI) provides a sustainable approach to cleaner ironmaking. In this research, for analyzing hydrogen-based DRI in pellet scale, the random pore model (RPM), the most sophisticated non-catalytic gas-solid model, is applied to determine the effects of structural parameters, including pore-size parameter (ψ), Thiele modulus (ϕ), and product layer resistance (β), along with operational parameters such as pressure, temperature, and gas composition. The PDE equations of RPM were solved numerically using the method of lines together with a finite-difference discretization in space. The effects of parameters ψ and ϕ were investigated, revealing that the reaction rate increases with larger pores and decreases with higher values of ϕ over length and time. Kinetics resemble the unreacted shrinking core model (USCM) for small particles, while pore structure dominates for large particles. Parameter determination is influenced by ϕ changes, shifting control from chemical kinetics to diffusion, with operating conditions impacting reaction rate enhancement. Investigations revealed that as ϕ increases from 0.454 to 1.454, a 6 % conversion gradient forms from the pellet center to the surface. Additionally, at 700°C, reducing the temperature by 100°C slows conversion by 15.45 minutes while increasing it accelerates conversion by 4.55 minutes.

Study of a Copper Oxide Leaching in Alkaline Monosodium Glutamate Solution

Oxide copper minerals are commonly extracted via acidic leaching, using acids such as H2SO4, HCl, or HNO3. These strong acids are the most widely used because of their high dissolution kinetics. However, their main concern is the high acid consumption because copper oxide deposits contain large amounts of acid-consuming gangue. This paper proposes using an alternative aqueous alkaline monosodium glutamate (MSG) system to leach copper oxide minerals. Tenorite (CuO) was used as the copper oxide mineral under study. The influence of process variables (such as temperature and glutamate concentration) and kinetics of this system on copper leaching from tenorite were studied. The results showed that temperature has a significant effect on copper dissolution rates. Increased temperature from 15 °C to 60 °C enhanced the copper extraction from 9.1% to 97.7% after 2 h. Leaching kinetics were analyzed using the shrinking core model (SCM) under various conditions, indicating that the leaching rate presented a mixed control. This method, however, fails to describe leaching for broad particle sizes due to its requirement for single-sized solid grains. This study demonstrated that a large particle size distribution in tenorite supported a successful extension of the SCM for leaching it from mixed glutamate solutions. The activation energy for the 15–60 °C temperature range was calculated to be 102.6 kJ/mol for the chemical control.

Dissolution behavior of hematite in H2SO4 solution: A kinetic analysis and its importance on the zinc hydrometallurgical hematite process

Here, the effect of H2SO4 concentration, temperature, liquid to solid ratio and particle size on the dissolution behavior of industrial hematite in H2SO4 solution. Among them, temperature and H2SO4 concentration have significant effects on the dissolution efficiency of Fe from industrial hematite. Below 363.15 K, the dissolution efficiency of Fe increases with the increase of temperature, but the opposite is true above 363.15 K. Increase H2SO4 concentration to promote the dissolution of industrial hematite. Liquid-solid ratio and particle size had little effect on the Fe concentration after dissolving at 180 min, but it has a significant influence on the Fe dissolution efficiency. The Fe dissolution efficiency of hematite with large particle size is significantly higher than that with small. Shrinking core model with inert reactant layer was employed to describe the dissolving kinetics of industrial hematite in H2SO4 solution. In the temperature range of 303.15 − 343.15 K, the interfacial chemical reaction control is the rate-limiting step. Apparent activation energy (Ea) is 48.1 kJ·mol−1. Based on this, four methods were recommended to prevent the re-dissolution of hematite in industrial practice: (1) increasing the reaction temperature, (2) extending the residence time of hematite in high temperature autoclave, (3) reducing the acidity of the slurry in autoclave though add neutralizer, (4) separating immediately hematite from slurry discharged from the autoclave. This work is of great practical value in terms of iron removal and recycle from the ZnSO4 solution though the hematite process with efficient, clean and low temperature at 423.15 K.

Copper leaching from complex chalcopyrite-rich ores: Utilizing mechanical activation and wastewater-based sulfuric acid system

Complex chalcopyrite-rich ore is crucial in global copper resources, but is highly refractory in conventional sulfate leaching system. In this paper, we explore the leaching of complex chalcopyrite-rich ores employing a mechanically activated pretreatment combined with wastewater with high concentrations of chloride. The investigation delves into various parameters, including reaction temperature (60 to 90 °C), sulfuric acid concentration (0.005 to 2.0 M), chloride concentration (0 to 1.5 M), liquid/solid ratio (0 to 200), stirring speed (100 to 580 rpm), leaching time (0 to 4 h) and grinding time (0 to 7 h), to evaluate their impact on copper recovery from complex chalcopyrite-rich ores. Furthermore, a comprehensive kinetic analysis of copper leaching behavior was studied, encompassing specific surface area, amorphization degree, grain size, and microstrain. In the sulfuric acid system utilizing wastewater, the presence of mechanical activation and chloride content enhances copper leaching while mitigating the passivating effect of elemental sulfur. Notably, following a leaching period of 4 h at 80 °C, the copper leaching efficiency remarkably reached 89.46 %. In addition, kinetic analysis of copper leaching at temperatures ranging from 60 to 90 °C via a shrinking core model with R2 > 97 %, indicates that the leaching process of copper is primarily governed by solid product layer diffusion, with an activation energy of 54.32 kJ/mol. These findings highlight the efficacy of the proposed approach in optimizing copper recovery from complex chalcopyrite-rich ores, offering insights into the underlying mechanisms driving the leaching process.

Comparative evaluation of diffusion kinetics of arsenic adsorption on iron (oxy) hydroxides containing biopolymer nanocomposite beads

Exposure to arsenic-contaminated water poses great health risks to mankind. Nanocomposite beads have been proven to be an effective alternative for large-scale treatment of arsenic-loaded water. The larger size of the beads makes the adsorbent retrieval process less energy-intensive and prevents accidental leaching of nanoparticles into the surrounding environment. Adsorption using macroporous beads is predominantly a diffusion-controlled process. Therefore, in the present study, the shrinking core model (SCM) was used to compare and evaluate the diffusion kinetics of arsenic adsorption using in-situ precipitated iron (oxy)hydroxide alginate (IIAB) and chitosan beads (IICB). Simulated dynamic nondimensional liquid phase arsenic concentration profiles fit well with the experimental data (SSE = 0.018–0.025). External mass transfer coefficient (kf) and effective diffusivity coefficient (De) for both kinds of beads at different initial arsenic concentrations (C0 ∼ 1 mg.L−1 and 5 mg.L−1) were derived. By comparison of diffusivity values and the simulated concentration front profiles, it was observed that chitosan provided a better porous polymer template with more easily accessible adsorption sites covering up to 85 % of the beads’ volume. Comparison with progression conversion models has also been made to test the effectiveness of SCM fitting.

Multi-dimensional CFD-Mask R-CNN and CFD-watershed segmentation approach for multiphase non-catalytic gas-solid reactions: A case study for hydrogen reduction of porous iron oxide pellets

The direct reduction of iron oxide (DRI) using hydrogen is a promising method for clean steelmaking. Previous studies used one-dimensional models to explore this non-catalytic gas–solid reaction, but they lacked accuracy in assessing the impact of pellet shape. To tackle this issue, a multi-dimensional computational fluid dynamic (CFD) method has been employed, integrating a novel porous three-interface unreacted shrinking core model (USCM) to explore the effects of pellet shape through multiphase reactions of Fe2O3 → Fe3O4 → FeO → Fe by pure hydrogen. The model incorporates Knudsen, molecular, and effective diffusion mechanisms, alongside a continuous porosity function. Validation against previous experiments within a temperature range of 800–1000 °C and varying porosity is performed by solving four partial differential equations (PDEs) of mass and momentum balance in a porous media using the finite element method (FEM). Subsequently, a dataset comprising 754 images of pellets from the industrial DRI unit is collected and applied for the mask region-based convolutional neural network (Mask R-CNN) algorithm coupled with CFD, to draw geometries and simulate DRI to study indentations and protrusions of pellets. Furthermore, watershed segmentation is applied to investigate the shapes and real sizes of pellets from their images. The Mask R-CNN achieves intersection over union (IoU), precision, and recall percentages of 86.1 %, 87.3 %, and 87.2 % on average, respectively. Pellet shape investigations reveal notable discrepancies in wustite phase profiles and porosity. A nuanced impact is discerned regarding the DRI in 2D shape deviation, while 3D model errors in solid conversion time range from 3 % to 12.8 %.

Low-Grade Ilmenite Leaching Kinetics Using Hydrochloric Acid: RSM and SCM Approaches

Minerals containing TiO2 are common in Indonesia, such as ilmenite in iron sand deposits scattered along the country's coasts. Ilmenite is an important source of titanium. One method for making TiO2 from ilmenite is by solubilizing both the Fe and Ti elements in HCl and then immediately hydrolyze the Ti. The leaching of low-grade ilmenite (ground to 0.177-0.149 mm) is studied kinetically by HCl in a stirred reactor. The research was conducted using the caustic fusion method followed by HCl leaching. The leaching reaction kinetics at the optimum conditions are analyzed using response surface methodology (RSM) with a second-order polynomial equation model and SSE with the shrinking core model (SCM). The results showed that HCl concentration and leaching time were directly proportional to the leached titanium concentration. In contrast, the leaching temperature was inversely proportional. The optimum operating conditions were obtained at a temperature of 30 °C, 9 M HCl, and 120 min of leaching time. The shrinking core model is a better representation of the kinetics than RSM with a second-order polynomial equation model. Based on SCM, the rate of the leaching reaction of titanium from low-grade ilmenite is controlled by diffusion through the ash layer.

Enhanced weathering for CO2 removal using carbonate-rich crushed returned concrete; a pilot study from SE Ireland

A 1.21-ha pilot study in SE Ireland investigated crushed returned concrete (CRC), applied at a rate of 7.5 tonnes/ha as a soil amendment for carbon dioxide removal (CDR) by enhanced weathering (EW) over a 10-month period. Most, but not all amended sites showed enhanced concentrations of calcium and bicarbonate in shallow soil waters compared with adjacent controls. Soil pH increased rapidly by 0.3 to >1 pH units (5.75 ± 0.25 (n = 8) in controls to 6.5 ± 0.7 (n = 24) at amended sites), with greatest increases in soils that had lowest initial pH (<6.0). Aside from one site where concentrations continued to increase, calcium (1.76–0.39 mM Ca) and bicarbonate (4.06–0.64 mM) values in soil waters declined gradually over the course of the study, consistent with rapid initial dissolution and progressive exhaustion of the fine-grained fraction, as indicated by a shrinking-core model. Most sites exhibited high bicarbonate to cation ratios (1.2–2.2) consistent with CRC dissolution by soil carbonic acid, although two sites adjacent to the field-boundary river that floods periodically showed evidence for strong acid (nitric) dissolution. Enhanced bicarbonate levels in soil waters at amended sites compared with controls, coupled with a downward-flush hydrological model driven by annual effective rainfall to calculate bicarbonate export and a simple stoichiometric correction for nitric acid weathering, indicate gross CDR rates in the range zero to 0.52 tonnes CO2/ha (69 kg CO2/tonne), limited by bicarbonate export rather than weathering rates. Further optimisation of the CDR efficiency of this material should be possible using strategies to avoid or pre-neutralise non-carbonic soil acids and by taking account of sub-aerial carbonation at the post-crushing, pre-amendment stage that arises when the material is crushed in preparation for EW applications. A simplified life-cycle analysis indicates that a discount of about 11% should be applied to account for CO2 emissions from crushing, transport and spreading operations.

Decomposition of zinc ferrite-based solid waste by reductive leaching: Leaching kinetics and mechanism

Zinc ferrite-based solid waste is a vital zinc and iron secondary source in view of the numerous zinc ferrite will be ineluctably produced and enters into slags or residues during zinc smelting process. In this study, a reductive leaching process with zinc sulfide powder was employed to decompose zinc ferrite from solid waste. The leaching efficiency of zinc and iron can reach 90.27 % and 81.96 %, respectively, while the process went to the 90th min at 90 ℃ under the conditions: sulfuric acid concentration of 500 g/L, liquid-to-solid ratio of 20 mL g−1, mass ratio of silver flotation tailings to zinc sulfide of 5/1, silver flotation tailings particle size of + 180–250 μm, rotary speed of 400 rpm. Then, this leaching process confirmed to shrinking core model and was conducted by surface chemical reaction after kinetics and thermodynamics investigations. Ultimately, according to various tested data, the corresponding reaction mechanism was speculated as: Fe3+ was reduced to Fe2+ by zinc sulfide and hydrogen sulfide which was the product of zinc sulfide with H+, resulting in potential reduction and H+ activity elevation, accelerating zinc dissolution eventually. Meanwhile, almost all zinc sulfide and hydrogen sulfide were oxidized to monomorphic sulfur by Fe3+ where the utilization ratio of zinc sulfide was 97.28 %.

Isothermal reduction and comparative analysis of reaction kinetics of sponge iron produced from hematite-charcoal reaction using non-contact direct reduction method

The challenge of making sponge iron, or direct reduced iron (DRI), is hard to overstate. These are a key feed for metallurgical operations while iron extraction sets these limits, which include scarcity of metallurgical coke, poor environmental impact, and high production cost. Thus, the non-contact direct reduction process of DRIs has the potential to significantly reduce carbon deposition and CO2 emission from the ironmaking process. This work produced sponge iron from commercially acquired hematite ore using an alternative reducing agent (i.e. charcoal) under specified isothermal conditions. Comparative analysis of reaction kinetics models including Ginstein−Brounshtein and Shrinking core models was also performed to ascertain the resistances that control the reaction rate for reduction degree up to 98.1%. The reduction kinetics were found to be described by reaction control time and activation energies based on a shrinking core model as the reduction time lasted for 120 min at temperatures 843–1273 K. At temperatures above 973–1073 K, the rate-limiting step was found to be solely an interfacial chemical reaction process, with an apparent activation energy of 196.1 kJ/mol. In addition, a slowing trend was observed for iron ore sample sizes 10–20 mm as a result of ash layer infiltration around the inner-core structure of the DRI metal matrix. The DRI morphological characteristics were performed using Scanning Electron Microscopy (SEM) and Electron Dispersive Spectrometry (EDS) to ascertain the mineralogical and morphological properties of the DRI samples. The XRF analysis confirms that the raw iron ore sample is hematite. Its iron content is 70.04% metallic iron (TFe) which has 83.59% Fe2O3 The SEM/EDS image also revealed the presence of micropores on the DRI morphology. This indicates that the reduction ratio and swelling extent rise with the temperature and time. This happens for all DRI sizes. However, the EDS result confirms the presence of gangue elements within the DRI metal matrix and mineralogical structure. The DRI contains very high silicon content up to 33.90%. So, a fluxing experiment is needed using limestone (CaCO3) or quicklime (CaO) quicklime to remove gangue (silicate, aluminate) from the DRI matrix. At the set reduction temperatures, the largest metallization degree of 93.05% at 1273 K for a reduction time of 120 min was achieved. This showed that the overall reduction process still follows the expected chronological order since the NDR process uses CO gas from preheated charcoal. This makes DRI be produced from raw hematite under non-contact reduction bases. Therefore, the NDR technique offers a viable option for sponge iron production in modern-day iron and steelmaking processes.

In-situ oxidation for selective lithium extraction from spent LiFePO4 cathodes by low acid dosage

Recovery of lithium from spent lithium iron phosphate batteries is crucial to alleviating the storage of lithium. This study proposes a method for the selective recovery of lithium from spent lithium iron phosphate battery cathodes using a leaching system of H2SO4 and H2O2. Efficient and selective lithium recovery was achieved through in-situ oxidation of lithium iron phosphate driven by a low acid dosage, and the mechanism of selective lithium recovery was investigated by precipitation experiments of Fe2+ and PO43−. The shrinking core model was used for the kinetic analysis of the leaching process, and the results suggested that the leaching process was controlled by the internal diffusion of the product layer. Moreover, essential leaching parameters such as acid concentration, H2SO4 dosage, H2O2 dosage, leaching time, and leaching temperature were systematically investigated. The results showed that the leaching rate of Li reached 97.95 % along with a selectivity of 99.60 %, which meets the standard of the battery-grade Li2CO3, while the leaching rate of both Fe and P was less than 1 %.

Crystallization of battery-grade lithium carbonate with high recovery rate via solid-liquid reaction

Lithium carbonate (Li2CO3) stands as a pivotal raw material within the lithium-ion battery industry. Hereby, we propose a solid-liquid reaction crystallization method, employing powdered sodium carbonate instead of its solution, which minimizes the water introduction and markedly elevates one-step lithium recovery rate. Through kinetic calculations, the Li2CO3 solid-liquid reaction crystallization process conforms by the Avrami equation rather than shrinking core model, which means the dissolution rate of Na2CO3 is the most important factor affecting the reaction process. The effects of reaction conditions such as temperature and stirring speed on the Li2CO3 precipitation behavior were evaluated. The results indicated that temperature is a most essential parameter than other reaction conditions or stirring speed. The exceptional 93% recovery of Li2CO3 at 90 °C with a remarkable purity of 99.5% was achieved by using 1.2 M ratio of Na2CO3/Li2SO4. This method provides a new idea for the efficient preparation of battery-grade Li2CO3.

An experimental investigation and predictive modeling using machine learning technique for reclamation of metal values from scrap NdFeB magnets

Neodymium-Iron-Boron (NdFeB) magnets are widely used in various industries due to their exceptional magnetic properties, such as high coercivity, remanence, and maximum energy product. These magnets consist of rare earth elements (REEs) viz., neodymium (Nd), praseodymium (Pr), and Dysprosium (Dy), along with other metals. With the ever increasing demand for REEs and the need to bridge the supply gap, it is crucial to develop alternative methods for their extraction. Recycling metal from scrap magnets is a promising approach to address the pressure on the supply chain and work towards sustainable development. The primary goal of this study is to generate a predictive model based on machine learning to determine the optimal conditions for metal recovery from scrap NdFeB magnets through water leaching after chloridizing roasting. Bench-scale leaching experiments were carried out to generate a dataset for statistical process optimization and machine learning analysis. The leaching kinetics of neodymium was also explored, and mixed-controlled shrinking core model was found to be most suitable, with an activation energy of 58.11 kJ/mol in the temperature range of 25– 95 °C. This study is the first to utilize a machine learning approach to analyze the potential process variables and their impact on metal recovery from calcined NdFeB magnet powder. A comparative analysis between experimental and machine learning approaches is presented to predict the optimal conditions for selective recovery of metal values from scrap NdFeB magnets. The maximum efficiency of extraction of metal ions was found to occur at a temperature of 95 °C, solid to liquid ratio of 125 g/l, and leaching duration of 60 min.