General Black Mass Process Steps
1. Feed Preparation
Black mass is received, characterized, and prepared for chemical processing. Depending on the requirement, this may involve drying, screening, slurry preparation, or controlled feeding.
2. Leaching
Selected chemicals are used to dissolve valuable metals from black mass into solution under controlled conditions such as temperature, pH, residence time, and agitation.
3. Solid-Liquid Separation
After leaching, undissolved solids are separated from the metal-rich solution using filtration, settling, or other separation methods.
4. Purification and Impurity Removal
Impurities are removed from the solution to improve downstream metal recovery and product quality.
5. Metal Separation and Recovery
Target metals such as cobalt, nickel, manganese, and lithium are selectively recovered through suitable hydrometallurgical methods such as precipitation, crystallization, solvent extraction, or other separation techniques based on project requirements.
6. Copper and Aluminum Handling
Copper and aluminum fractions are managed based on feed composition and process route. These may be separated mechanically, chemically, or through suitable recovery steps.
7. Effluent and Residue Management
Process residues and liquid streams are managed through appropriate neutralization, treatment, and handling systems as per applicable environmental norms.
Note
Actual process configuration depends on battery chemistry, black mass quality, recovery targets, chemical route, product specification, and regulatory requirements.