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International Journal of Technical Research and Applications e-ISSN: 2320-8163,
www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30
25 | P a g e
PREPARATION OF MANGANESE
NANOPARTICLES AND VALUABLE SALTS
FROM SPENT DRY BATTERY CELLS
Mahmoud A. Rabah1, Taha M.A. Razek2, Omar M. Abdel Aziz3
1
Chemical and electrochemical treatment Lab, Mineral Processing Dept. Central Metallurgical R&D Institute,
P.O>Box 87 Helwan Cairo Egypt
2
Assoc. Prof. Environmental chemistry,
Institute for environmental studies and research, Ein Shams University
3
Director, Great Cairo Potable water Co.
1
mahmoud.rabah@ymail.com, 1
mrabah010@gmail.com, 2
Tahaelsabbagh@yahoo.com, 3
Omermhelmy@gmail.com
Abstract- This work shows a method to prepare manganese
nanoparticles on carbon substrate and some inorganic and organic
salts such as carbonate, nitrate, chloride, citrate and acetate from
spent dry battery cells. The method involves dismantling the cell
followed by sulfuric acid leaching of the whole contents at
temperatures up to 75°C for 3 hours. The leaching products were
filtered and the metals went into solution were determined. Metals
other than manganese were chemically separated whereby
manganese hydroxide was precipitated at pH 8. Nanoparticles of
manganese were prepared by direct reduction of the hydroxide
using hydrazine hydrate. The hydroxide salt reacted with the
respective acid to prepare the required salt. Results revealed that
manganese content in the spent battery cell amounts to 22 % by
weight. Leaching extent in sulfuric acid increased with the
increasing the acid molarity up to 3, temperature of leaching up to
75 °C, leaching time up to 3 hours and stirring conditions. The
quality of the products have been characterized by XRD, SEM and
FT-IR investigations. The activation energy of the acid leaching of
manganese amounts to kJ.mol.
Key words: Manganese, hydrometallurgy, nanoparticles, spent
dry cell battery
I. INTRODUCTION
There are four main types of batteries
A. Disposable dry-cell batteries
It includes: 1- Zinc-carbon and zinc-chloride batteries are
used in low energy use appliances such as clocks and radios.
They are often found in products sold with disposable batteries,
as they are cheap. 2- Alkaline batteries are used in equipment
such as MP3 players, torches or toys. They are longer lasting and
less prone to leaking than zinc carbon and zinc-chloride
batteries. 3- Button cell batteries contain mercury, silver, lithium
or other valuable heavy metals. Mercuric oxide button cells are
used for hearing aids, pacemakers and photographic equipment.
4- Zinc-air batteries are an alternative to mercuric oxide button
cells. They may be used in hearing aids and radio pagers. 5-
Silver oxide button cells are a type of alkaline battery used in
electronic watches and calculators. 6- Lithium button cells are
also used in watches and in photographic equipment.
B. Recycling disposable batteries
1- Zinc-carbon, 2- alkaline manganese batteries and 3-
button cell
C. Rechargeable dry-cell batteries
1- Nickel cadmium (NiCd) batteries, Nickel-metal hydride
(NiMH) batteries Lithium-ion and lithium ion polymer (Li-
Ion) Batteries
D. Recycling rechargeable batteries 1- NiMH batteries and 2-
NiCd batteries
Spent dry battery cells (DBCs) are processed by a variety of
methods, including size reduction, screening, magnetic
separation, and mechanical and chemical processes for
recovering zinc and ammonium salt. [1]. Nicolae [2] developed
mechanical separation for Leclanché (ammonium chloride-
manganese dioxide-zinc) batteries in which the powdered
manganese oxide and other compounds were dissolved in
concentrate HCl, then oxidized to obtain MnO2 and Zn(OH)2 The
mixture was washed with dilute HCl to dissolve Zn(OH)2 and
zinc was recovered as ZnCl2 Shaoguo [3] also recovered zinc
and NH4Cl from spent DBCs. Studies on the effect of
temperature on the recovery process for DBCs was also
performed. The powder feed of the spent batteries was leached
after shredding and grinding with 1–50 percent H2SO4 and/or
HCl under inert atmosphere or in the presence of hydrazine
sulfate, a reducing agent, to recover zinc and manganese. Zinc
was precipitated with oxalic acid and recovered by filtration;
manganese was then precipitated in the form of mixed hydroxide
and carbonate using Na. Lindermann et al. [4] applied a novel
procedure including mechanical separation for steel and plastic
casings followed by leaching in H2SO4 Zinc has been recovered
by solvent extraction or by electrolysis [5,6,7]. The pyro-
metallurgical recovery of zinc from DBCs in an oxidation or
rotary furnace has been reported [8,9]. Zinc and its compounds
were vaporized and entered a bubbling type condenser. The
recovery processes were carried out under non oxidizing
atmosphere at 1,000–1,150°C, by carbon reduction, by carbon-
containing materials, or by vacuum distillation [10]. Rabah and
El- Sayed [11] studied the recovery of zinc from zinc-waste
materials in which the coarse fraction was heated with
10%NHCl at 600°C to produce a zinc recovery efficiency of
about 89%. Several pyro-metallurgical and hydro-metallurgical
processes for the recycling of batteries were proposed[12].
Hydrometallurgical processes are usually characterized by
different pretreatment stages, followed by leaching and
separation of different metals by electrolysis, liquid-liquid
extraction, or selective precipitation. The Batenus process treats
International Journal of Technical Research and Applications e-ISSN: 2320-8163,
www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30
26 | P a g e
all types of batteries (except for button cells); copper, nickel, and
cadmium are selectively recovered by ion exchange, whereas
zinc and manganese were separated by liquid-liquid extraction
and electrodeposited in two cells to obtain metallic zinc and
manganese dioxide [13]. In the Recupyl process zinc and
manganese are recovered as carbonates or other compounds [14].
Revabat process treats only zinc-carbon and alkaline batteries;
after sorting, batteries are dismantled and treated by sulfuric acid
solution, from which Mn and Zn are recovered as oxides or salts
[15]. Toro et al. [16] developed a patented process for the
recycling of alkaline and zinc-carbon spent batteries, where the
metals are leached in acid solution in the presence of
carbohydrates as reducing agents; after purification of solution,
metallic zinc and manganese dioxide are recovered by electro
winning. Veloso et al. [17] proposed a process in which metals
are leached by H2SO4 and H2O2; after that manganese and zinc
are selectively precipitated by KOH. De Souza and Tenório [18]
described a similar process performed by an acid leaching, but
zinc and manganese are simultaneously recovered as metallic
zinc and manganese dioxide by electro winning. Salgado et al.
[19] and Devi et al. [20] investigated liquid-liquid extraction
separation of zinc and manganese after a leaching step with
H2SO4. De Michelis et al. [21] developed a statistical design in
leaching of alkaline and zinc-carbon battery paste by using
sulfuric acid and oxalic acid as reducing agent. Ferella et al. [22]
studied acid leaching of battery paste whereby zinc was
recovered by electrolysis and a blend of manganese oxides was
obtained by roasting of the leaching solid residue. Sayilgan et al.
[23] have studied leaching of battery samples (zinc-carbon,
alkaline, and mixture of them) by sulfuric and hydrochloric acid
in the presence of oxalic acid as reducing agent. Xi et al. [24]
proposed a process for production of Mn-Zn ferrites using spent
alkaline batteries: the powder is leached by H2SO4 and H2O2 as
reducing agent, then NaOH is used to adjust the pH value in the
range 3–5. Mn and Fe salts are added to have the right molar
ratio, and after precipitation with NH4HCO3 in pH range 6.0–9.5
the precipitate was calcined at C to obtain ferrite. The process of
Nan et al. [25] replaced (NH4)2C2O4 as a precipitating agent.
Application of manganese nanoparticles are in magnetic data
storage, magnetic resonance imaging and Biosensors, textile and
coating, nanowires, plastics and nanofibers. Magnetic resonance
imaging (MRI) is a routine diagnostic tool in modern clinical
medicine.
The objective of this study is to prepare valuable manganese
inorganic and organic salts from spent dry battery cells by
applying friendly and cost-effective method. Parameters
affecting the efficiency and quality of the end products, such as
time, temperature, pH value, and stoichiometric ratio of the
leaching solutions, were studied.
II. EXPERIMENTAL
A. Materials
a. About ten Kg of the spent dry battery sample were
supplied by the waste collection stores, Cairo. The
sample was washed with water and left to rinse in
normal ambient conditions.
b. The carbon substrate for preparation of manganese
nanoparticles was prepared from two carbon types. The
first type was a thin sheet of artificial graphite cut from
a mother plate of Carbon Lorene France. The second
type was glassy carbon obtained from the carbon rod of
the dry battery after dismantling. Both two types were
freed from wax by heating at 300°C in normal
conditions. The de-waxed samples were washed and
cleaned by washing in acetone.
c. Chemicals used for leaching, precipitation, separation
and salts preparation were chemically pure grade.
Sulfuric, nitric citric, formic, acetic acids and
ammonium hydroxide 30% were of ADWIC production
(Egypt)
d. Mono distilled water was used for leaching and
precipitation steps.
B. Method of preparation of manganese nanoparticles
Manganese nanoparticles were prepared from the spent
black paste of the dry battery cell by acid leaching of the element
in sulfuric acid. The sulfate solution was treated with ammonia
solution to precipitate manganese hydroxide at pH 8.The
precipitate was washed with water and suspended in glucose
solution.
C. Measurement of the physic-chemical properties
Determination of metals available in the spent battery
sample was conducted applying the standard analytical methods
given in the literature. Spectrophotometer U.V visible
spectrophotometer type UV 260 (Shimadzu) was used for the
determination of manganese content in the samples [26]. Zinc
was determined titrametrically against EDTA using Eriochrome
Black T as an indicator [27]
Determination of alkali metals Sodium, Potassium and
calcium were determined with the help of photometric analysis
applying a flame photometer type Chloride ion was determined
gravimetrically by silver nitrate precipitation 2.3 Method of
preparation of the manganese salts
Figure 1 shows the conceptual flow sheet of the applied
method for preparation of manganese nanoparticles and
manganese salts. The dry battery cell type was A, AAA size of
energizer production
International Journal of Technical Research and Applications e-ISSN: 2320-8163,
www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30
27 | P a g e
Fig. 1 the conceptual flow sheet of preparation of manganese nanoparticles and valuable salts
From spent dry battery cell
.
III. RESULTS
Table 1 The contents of the spent dry battery cell
material Weight, g Basis of
determinat
ion
Weight
% in
battery
Stainless cover 1.055 1.56
Cartoon 3.092 4.75
Carbon rod 5.139 7.60
Polymer Insulator 1.403 2.07
Plastic ring 1.796 2.65
metal cup 14.534 21.5
Black paste
Water soluble salts
30.35
10.20
C/MnO2 59.99
Total 67.6 100
Table 1 shows the contents of the spent dry cell batteries of
type A and AAA. It can be seen that the black powder (carbon +
manganese dioxide) content amounts to 40.55 g out of 67.6 g for
the whole battery weight. The net manganese dioxide weight
amounts to 25 g
The weight of carbon in black paste amounts to 15.55. It
was removed by heating at temperatures up to 1000°C till
constant weight. Fig. 2a,b shows the XRD of the black paste.
Fig. 2a XRD pattern of black paste before heating
Fig. 2b XRD pattern of black paste after heating
Figure 3a,b shows the weight loss of the black paste as a
function of temperature. Figure 4 shows the TGA of this paste
after heating at temperatures up to 1000°C.
International Journal of Technical Research and Applications e-ISSN: 2320-8163,
www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30
28 | P a g e
Fig. 3a the weight loss of black paste as a function of
temperature
Fig. 3b The effect of temperature on the percent weight loss
of black paste
% , weight, g
Figure 4 shows TGA of the black paste. It can be seen that a
significant loss in weight takes place at ≥ 650 °C.
100 200 300 400 500 600 700 800 900
Temperature /°C
-1
0
1
2
3
4
5
6
7
8
DSC /(µV/mg)
75
80
85
90
95
100
TG /%
-6
-5
-4
-3
-2
-1
0
1
DTG /(%/min)
[1.1] black.sss
TG
DSC
DTG
[1.1][1.1]
[1.1]
exo
Fig. 4 The TGA curve of this paste after heating at
temperatures up to 1000°C.
Figure 5 shows the extent of water soluble salts present in the
black paste of spent ever ready battery type. It can be seen that
the maximum extent of 0.17 % was attained with boiling water
whereas the least extent of 0.08 % took place in cold water.
Fig. 5 the extent of water soluble matters in the spent battery
as affected by temperature of water washing
Weight, g Commulative weight, %
Fig. 6 the particle size distribution of the black paste of spent
dry cell
Figure 7 The extent of leaching of Mn metal from the spent
dry cell using different mineral acids for 3 hours.
Figure 7 shows the extent of leaching of manganese metal from
the spent dry cell using different mineral acids for 3 hours at
room temperature. It is seen that the extent of leaching decreases
in the order sulfuric > HCl and nitric acid. It is also seen that
leaching increases with time whereby the maximum value takes
place at 180 minutes.
Figure 8 shows the extent of leaching zinc in nitric acid as
affected by the acid normality at room temperature. It is seen that
zinc leaching increases with increase in acid normality passing
through a maximum with 3 N acid.
Fig.9 shows the leaching results obtained with sulfuric acid. It is
seen that leaching decreases with increase in acid normality and
temperature. It is seen that the extent of leaching at room
temperature overweighs leaching in boiling conditions. It is
noted that leaching using dilute acid (N,≤3) is more efficient
than using more concentrated acid.
Figure 10 shows the leaching extent of manganese in sulfuric as
a function of particle size of the black paste. It is seen that the
extent of leaching is inversely proportional to the grain size of
the black paste.
Fig. 8 The extent of leaching zinc in nitric acid as affected by
acid normality at room temperature.
International Journal of Technical Research and Applications e-ISSN: 2320-8163,
www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30
29 | P a g e
Fig. 9 Leaching of manganese in sulfuric acid having
different normality and temperature values
Fig. 10 the effect of particle size of the black paste on the
extent of leaching manganese in sulfuric acid
Figure 11 shows the SEM of the nanoparticles of manganese as
prepared on carbon substrate
Fig. 11 SEM image of manganese nanoparticles on carbon
substrate.
Table 2 shows the data for preparation of some inorganic and
organic salts of manganese from its hydroxide salt and the
respective acid.
Table 2 Data for the preparation of some manganese salts
Product
of Mn
Weight/volume of reagents
Mn(OH)2 CO2 Respective
acid
Acid
conc.
CO3
2-
(rose)
10 g 4.947 g
(NO3)2-
(pink-
rose)
10 g 75 ml 3N
(HNO3)
Cl-
(brown)
10 g 44.8 ml 5N (HCl)
acetate 13.49 ml Glacial
acetic
acid
citrate 43.247 In 100 ml
water
IV. DISCUSSION
Recovery of spent dry battery cells has dual benefits. It
helps to get rid of the waste of hazardous materials and obtain
valuable products of market value. The average quantity of the
used dry battery cells in Egypt increases dramatically on basis of
the increasing rate of the population development. In this
context, studies carried out to recycle the dry battery cells have
different issues and objectives. Some studies paid attention to the
zinc content alone whereas others paid attention to iron discs. In
some cases, agencies had their aim to recover black paste
altogether with zinc metal. The present study has its aim to make
use of all the contaminants of the dry cell battery in the country.
The experimental program started by dismantling the spent cell
with the help of a double toothed saw blade. Plate 1 shows a split
dry cell.
Table 1 shows the contents of the battery cell. XRD patterns
given in Figs 2a,b confirms the presence of these components.
Determination of carbon in the black paste was examined by
heating the black paste at temperatures up to 1000°C. the initial
weight loss taking place up to 400°C can be attributed to the loss
of moisture content and volatile salts such as ammonium
chloride and ammonia. The slight increase in weight loss taking
place within the temperature range 400-500°C is assigned to the
escape of zinc chloride. The drastic increase in weight loss at
600°C is due to the oxidation of the available carbon in the black
paste to carbon oxides(mono and dioxide)
2C + O2 2 CO ……………..(1)
2CO + O2 2CO2 ………….…(2)
.
The humidity detected in the cell upon cutting finds support from
the fact that the chemical reactions taking place during
discharging the battery generate water as follows:
.
Zn + NH4Cl ZnCl + NH4
+
……….(3)
NH4
+
NH3 + H+
……….....…(4)
2H+
H2 + 2 e …………..…(5)
2H + MnO2 H2O + MnO .……….(6)
and the overall reaction is:
Zn + NH4Cl +MnO2 ZnCl + MnO + H2O +2e ...(7)
The moisture content amounts to about 7.2% in the unused
cells. Zinc chloride and ammonia primary used in the
manufacture of the dry cells. During discharging of the battery,
excessive quantity of water generated and dissolves more zinc
chloride. This explains why the total weight of the water soluble
salts in the spent battery(22.5 %) is much higher as compared to
the new cell (7.2%). Results given in Fig. 5, is in a good
agreement with the solubility of zinc chloride in cold water
(432g/100g water) and hot water (635g/100 g water) [28]
The particle size distribution analysis of the black paste
given in Fig.6 shows that the finer particle size of <60 um helps
to enhance the oxidation-reduction reactions (Ox-Re) to take
place during the battery discharge at a high performance. This
imparts a convenient duty of the battery. On the contrary, if the
black paste has a larger grain size, it would decrease the
efficiency of the Ox-Re) and the battery duty as well.
International Journal of Technical Research and Applications e-ISSN: 2320-8163,
www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30
30 | P a g e
Leaching of zinc in different mineral acids (sulfuric, nitric
and HCl ) showed that the process is time dependent particularly
within the first 180 minutes. This phenomenon is ascribed to the
passivity action of the generated hydrogen gas evolving during
acid attack. Also the more concentrated acid has the same effect.
Dilute acids helps less quantity of hydrogen gas to build a gas
barrier on the zinc surface. The same explanation would be
applied to the acid leaching of manganese. Results of fig. 9
confirm this model. The effect of particle size of the paste on the
extent of acid leaching of manganese imparts that the surface
area of the fine particles are much higher than coarse particles. In
other words the surface subjected to acid attack is much more
available with fine particles as compared to the coarser one.
SEM image shows that the average grain size of the
nanoparticles, obtained in this work, amounts to nearly 10-30um.
REFERENCES
[1] C. Nicolae, Rom. RO , 90 (1988), p. 70.
[2] C. Shaoguo, “Comprehensive Utilization of Spent Dry Cells,”
Huaxue Shijie, 26 (11) (1985), pp. 427–428
[3] W. Lindermann et al., “Batenus Process for Recycling Battery
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[12] D. C. R. Espinosa, A. M. Bernardes, and J. A. S. Tenório, “An
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Journal of Power Sources, vol. 135, no. 1-2, pp. 311–319, 2004.
[13] W. Lindermann, Process for the recovery of raw materials from
presorted collected waste, especially scrap electrochemical
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907.
[14] F. Tedjar, Recycling used electric cells by hydrometallurgical
treatment (2003), Patent application WO 03/021 708.
[15] A. Serstevens, Process for the recycling of salt and alkaline
batteries (2001), Patent application EP 1 148 571.
[16] L. Toro, F. Vegliò, F. Beolchini, F. Pagnanelli, M. Zanetti, and G.
Furlani, Process and plant for the treatment of run-down batteries
(2006), Patent application EP 1 684 369.
[17] L. R. S. Veloso, L. E. O. C. Rodrigues, D. A. Ferreira, F. S.
Magalhães, and M. B. Mansur, “Development of a
hydrometallurgical route for the recovery of zinc and manganese
from spent alkaline batteries,” Journal of Power Sources, vol. 152,
no. 1-2, pp. 295–302, 2005.
[18] C. C. B. M. De Souza and J. A. S. Tenório, “Simultaneous
recovery of zinc and manganese dioxide from household alkaline
batteries through hydrometallurgical processing,” Journal of
Power Sources, vol. 136, no. 2, pp. 191–196, 2004.
[19] A. L. Salgado, A. M. O. Veloso, D. D. Pereira, G. S. Gontijo, A.
Salum, and M. B. Mansur, “Recovery of zinc and manganese
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[20] N. B. Devi, K. C. Nathsarma, and V. Chakravortty, “Extraction
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[21] I. De Michelis, F. Ferella, E. Karakaya, F. Beolchini, and F.
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[22] F. Ferella, I. De Michelis, and F. Vegliò, “Process for the
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[23] E. Sayilgan, T. Kukrer, F. Ferella, A. Akcil, F. Veglio, and M.
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[24] G. Xi, Y. Li, and Y. Liu, “Study on preparation of manganese-
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PREPARATION OF MANGANESE NANOPARTICLES AND VALUABLE SALTS FROM SPENT DRY BATTERY CELLS

  • 1. International Journal of Technical Research and Applications e-ISSN: 2320-8163, www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30 25 | P a g e PREPARATION OF MANGANESE NANOPARTICLES AND VALUABLE SALTS FROM SPENT DRY BATTERY CELLS Mahmoud A. Rabah1, Taha M.A. Razek2, Omar M. Abdel Aziz3 1 Chemical and electrochemical treatment Lab, Mineral Processing Dept. Central Metallurgical R&D Institute, P.O>Box 87 Helwan Cairo Egypt 2 Assoc. Prof. Environmental chemistry, Institute for environmental studies and research, Ein Shams University 3 Director, Great Cairo Potable water Co. 1 mahmoud.rabah@ymail.com, 1 mrabah010@gmail.com, 2 Tahaelsabbagh@yahoo.com, 3 Omermhelmy@gmail.com Abstract- This work shows a method to prepare manganese nanoparticles on carbon substrate and some inorganic and organic salts such as carbonate, nitrate, chloride, citrate and acetate from spent dry battery cells. The method involves dismantling the cell followed by sulfuric acid leaching of the whole contents at temperatures up to 75°C for 3 hours. The leaching products were filtered and the metals went into solution were determined. Metals other than manganese were chemically separated whereby manganese hydroxide was precipitated at pH 8. Nanoparticles of manganese were prepared by direct reduction of the hydroxide using hydrazine hydrate. The hydroxide salt reacted with the respective acid to prepare the required salt. Results revealed that manganese content in the spent battery cell amounts to 22 % by weight. Leaching extent in sulfuric acid increased with the increasing the acid molarity up to 3, temperature of leaching up to 75 °C, leaching time up to 3 hours and stirring conditions. The quality of the products have been characterized by XRD, SEM and FT-IR investigations. The activation energy of the acid leaching of manganese amounts to kJ.mol. Key words: Manganese, hydrometallurgy, nanoparticles, spent dry cell battery I. INTRODUCTION There are four main types of batteries A. Disposable dry-cell batteries It includes: 1- Zinc-carbon and zinc-chloride batteries are used in low energy use appliances such as clocks and radios. They are often found in products sold with disposable batteries, as they are cheap. 2- Alkaline batteries are used in equipment such as MP3 players, torches or toys. They are longer lasting and less prone to leaking than zinc carbon and zinc-chloride batteries. 3- Button cell batteries contain mercury, silver, lithium or other valuable heavy metals. Mercuric oxide button cells are used for hearing aids, pacemakers and photographic equipment. 4- Zinc-air batteries are an alternative to mercuric oxide button cells. They may be used in hearing aids and radio pagers. 5- Silver oxide button cells are a type of alkaline battery used in electronic watches and calculators. 6- Lithium button cells are also used in watches and in photographic equipment. B. Recycling disposable batteries 1- Zinc-carbon, 2- alkaline manganese batteries and 3- button cell C. Rechargeable dry-cell batteries 1- Nickel cadmium (NiCd) batteries, Nickel-metal hydride (NiMH) batteries Lithium-ion and lithium ion polymer (Li- Ion) Batteries D. Recycling rechargeable batteries 1- NiMH batteries and 2- NiCd batteries Spent dry battery cells (DBCs) are processed by a variety of methods, including size reduction, screening, magnetic separation, and mechanical and chemical processes for recovering zinc and ammonium salt. [1]. Nicolae [2] developed mechanical separation for Leclanché (ammonium chloride- manganese dioxide-zinc) batteries in which the powdered manganese oxide and other compounds were dissolved in concentrate HCl, then oxidized to obtain MnO2 and Zn(OH)2 The mixture was washed with dilute HCl to dissolve Zn(OH)2 and zinc was recovered as ZnCl2 Shaoguo [3] also recovered zinc and NH4Cl from spent DBCs. Studies on the effect of temperature on the recovery process for DBCs was also performed. The powder feed of the spent batteries was leached after shredding and grinding with 1–50 percent H2SO4 and/or HCl under inert atmosphere or in the presence of hydrazine sulfate, a reducing agent, to recover zinc and manganese. Zinc was precipitated with oxalic acid and recovered by filtration; manganese was then precipitated in the form of mixed hydroxide and carbonate using Na. Lindermann et al. [4] applied a novel procedure including mechanical separation for steel and plastic casings followed by leaching in H2SO4 Zinc has been recovered by solvent extraction or by electrolysis [5,6,7]. The pyro- metallurgical recovery of zinc from DBCs in an oxidation or rotary furnace has been reported [8,9]. Zinc and its compounds were vaporized and entered a bubbling type condenser. The recovery processes were carried out under non oxidizing atmosphere at 1,000–1,150°C, by carbon reduction, by carbon- containing materials, or by vacuum distillation [10]. Rabah and El- Sayed [11] studied the recovery of zinc from zinc-waste materials in which the coarse fraction was heated with 10%NHCl at 600°C to produce a zinc recovery efficiency of about 89%. Several pyro-metallurgical and hydro-metallurgical processes for the recycling of batteries were proposed[12]. Hydrometallurgical processes are usually characterized by different pretreatment stages, followed by leaching and separation of different metals by electrolysis, liquid-liquid extraction, or selective precipitation. The Batenus process treats
  • 2. International Journal of Technical Research and Applications e-ISSN: 2320-8163, www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30 26 | P a g e all types of batteries (except for button cells); copper, nickel, and cadmium are selectively recovered by ion exchange, whereas zinc and manganese were separated by liquid-liquid extraction and electrodeposited in two cells to obtain metallic zinc and manganese dioxide [13]. In the Recupyl process zinc and manganese are recovered as carbonates or other compounds [14]. Revabat process treats only zinc-carbon and alkaline batteries; after sorting, batteries are dismantled and treated by sulfuric acid solution, from which Mn and Zn are recovered as oxides or salts [15]. Toro et al. [16] developed a patented process for the recycling of alkaline and zinc-carbon spent batteries, where the metals are leached in acid solution in the presence of carbohydrates as reducing agents; after purification of solution, metallic zinc and manganese dioxide are recovered by electro winning. Veloso et al. [17] proposed a process in which metals are leached by H2SO4 and H2O2; after that manganese and zinc are selectively precipitated by KOH. De Souza and Tenório [18] described a similar process performed by an acid leaching, but zinc and manganese are simultaneously recovered as metallic zinc and manganese dioxide by electro winning. Salgado et al. [19] and Devi et al. [20] investigated liquid-liquid extraction separation of zinc and manganese after a leaching step with H2SO4. De Michelis et al. [21] developed a statistical design in leaching of alkaline and zinc-carbon battery paste by using sulfuric acid and oxalic acid as reducing agent. Ferella et al. [22] studied acid leaching of battery paste whereby zinc was recovered by electrolysis and a blend of manganese oxides was obtained by roasting of the leaching solid residue. Sayilgan et al. [23] have studied leaching of battery samples (zinc-carbon, alkaline, and mixture of them) by sulfuric and hydrochloric acid in the presence of oxalic acid as reducing agent. Xi et al. [24] proposed a process for production of Mn-Zn ferrites using spent alkaline batteries: the powder is leached by H2SO4 and H2O2 as reducing agent, then NaOH is used to adjust the pH value in the range 3–5. Mn and Fe salts are added to have the right molar ratio, and after precipitation with NH4HCO3 in pH range 6.0–9.5 the precipitate was calcined at C to obtain ferrite. The process of Nan et al. [25] replaced (NH4)2C2O4 as a precipitating agent. Application of manganese nanoparticles are in magnetic data storage, magnetic resonance imaging and Biosensors, textile and coating, nanowires, plastics and nanofibers. Magnetic resonance imaging (MRI) is a routine diagnostic tool in modern clinical medicine. The objective of this study is to prepare valuable manganese inorganic and organic salts from spent dry battery cells by applying friendly and cost-effective method. Parameters affecting the efficiency and quality of the end products, such as time, temperature, pH value, and stoichiometric ratio of the leaching solutions, were studied. II. EXPERIMENTAL A. Materials a. About ten Kg of the spent dry battery sample were supplied by the waste collection stores, Cairo. The sample was washed with water and left to rinse in normal ambient conditions. b. The carbon substrate for preparation of manganese nanoparticles was prepared from two carbon types. The first type was a thin sheet of artificial graphite cut from a mother plate of Carbon Lorene France. The second type was glassy carbon obtained from the carbon rod of the dry battery after dismantling. Both two types were freed from wax by heating at 300°C in normal conditions. The de-waxed samples were washed and cleaned by washing in acetone. c. Chemicals used for leaching, precipitation, separation and salts preparation were chemically pure grade. Sulfuric, nitric citric, formic, acetic acids and ammonium hydroxide 30% were of ADWIC production (Egypt) d. Mono distilled water was used for leaching and precipitation steps. B. Method of preparation of manganese nanoparticles Manganese nanoparticles were prepared from the spent black paste of the dry battery cell by acid leaching of the element in sulfuric acid. The sulfate solution was treated with ammonia solution to precipitate manganese hydroxide at pH 8.The precipitate was washed with water and suspended in glucose solution. C. Measurement of the physic-chemical properties Determination of metals available in the spent battery sample was conducted applying the standard analytical methods given in the literature. Spectrophotometer U.V visible spectrophotometer type UV 260 (Shimadzu) was used for the determination of manganese content in the samples [26]. Zinc was determined titrametrically against EDTA using Eriochrome Black T as an indicator [27] Determination of alkali metals Sodium, Potassium and calcium were determined with the help of photometric analysis applying a flame photometer type Chloride ion was determined gravimetrically by silver nitrate precipitation 2.3 Method of preparation of the manganese salts Figure 1 shows the conceptual flow sheet of the applied method for preparation of manganese nanoparticles and manganese salts. The dry battery cell type was A, AAA size of energizer production
  • 3. International Journal of Technical Research and Applications e-ISSN: 2320-8163, www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30 27 | P a g e Fig. 1 the conceptual flow sheet of preparation of manganese nanoparticles and valuable salts From spent dry battery cell . III. RESULTS Table 1 The contents of the spent dry battery cell material Weight, g Basis of determinat ion Weight % in battery Stainless cover 1.055 1.56 Cartoon 3.092 4.75 Carbon rod 5.139 7.60 Polymer Insulator 1.403 2.07 Plastic ring 1.796 2.65 metal cup 14.534 21.5 Black paste Water soluble salts 30.35 10.20 C/MnO2 59.99 Total 67.6 100 Table 1 shows the contents of the spent dry cell batteries of type A and AAA. It can be seen that the black powder (carbon + manganese dioxide) content amounts to 40.55 g out of 67.6 g for the whole battery weight. The net manganese dioxide weight amounts to 25 g The weight of carbon in black paste amounts to 15.55. It was removed by heating at temperatures up to 1000°C till constant weight. Fig. 2a,b shows the XRD of the black paste. Fig. 2a XRD pattern of black paste before heating Fig. 2b XRD pattern of black paste after heating Figure 3a,b shows the weight loss of the black paste as a function of temperature. Figure 4 shows the TGA of this paste after heating at temperatures up to 1000°C.
  • 4. International Journal of Technical Research and Applications e-ISSN: 2320-8163, www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30 28 | P a g e Fig. 3a the weight loss of black paste as a function of temperature Fig. 3b The effect of temperature on the percent weight loss of black paste % , weight, g Figure 4 shows TGA of the black paste. It can be seen that a significant loss in weight takes place at ≥ 650 °C. 100 200 300 400 500 600 700 800 900 Temperature /°C -1 0 1 2 3 4 5 6 7 8 DSC /(µV/mg) 75 80 85 90 95 100 TG /% -6 -5 -4 -3 -2 -1 0 1 DTG /(%/min) [1.1] black.sss TG DSC DTG [1.1][1.1] [1.1] exo Fig. 4 The TGA curve of this paste after heating at temperatures up to 1000°C. Figure 5 shows the extent of water soluble salts present in the black paste of spent ever ready battery type. It can be seen that the maximum extent of 0.17 % was attained with boiling water whereas the least extent of 0.08 % took place in cold water. Fig. 5 the extent of water soluble matters in the spent battery as affected by temperature of water washing Weight, g Commulative weight, % Fig. 6 the particle size distribution of the black paste of spent dry cell Figure 7 The extent of leaching of Mn metal from the spent dry cell using different mineral acids for 3 hours. Figure 7 shows the extent of leaching of manganese metal from the spent dry cell using different mineral acids for 3 hours at room temperature. It is seen that the extent of leaching decreases in the order sulfuric > HCl and nitric acid. It is also seen that leaching increases with time whereby the maximum value takes place at 180 minutes. Figure 8 shows the extent of leaching zinc in nitric acid as affected by the acid normality at room temperature. It is seen that zinc leaching increases with increase in acid normality passing through a maximum with 3 N acid. Fig.9 shows the leaching results obtained with sulfuric acid. It is seen that leaching decreases with increase in acid normality and temperature. It is seen that the extent of leaching at room temperature overweighs leaching in boiling conditions. It is noted that leaching using dilute acid (N,≤3) is more efficient than using more concentrated acid. Figure 10 shows the leaching extent of manganese in sulfuric as a function of particle size of the black paste. It is seen that the extent of leaching is inversely proportional to the grain size of the black paste. Fig. 8 The extent of leaching zinc in nitric acid as affected by acid normality at room temperature.
  • 5. International Journal of Technical Research and Applications e-ISSN: 2320-8163, www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30 29 | P a g e Fig. 9 Leaching of manganese in sulfuric acid having different normality and temperature values Fig. 10 the effect of particle size of the black paste on the extent of leaching manganese in sulfuric acid Figure 11 shows the SEM of the nanoparticles of manganese as prepared on carbon substrate Fig. 11 SEM image of manganese nanoparticles on carbon substrate. Table 2 shows the data for preparation of some inorganic and organic salts of manganese from its hydroxide salt and the respective acid. Table 2 Data for the preparation of some manganese salts Product of Mn Weight/volume of reagents Mn(OH)2 CO2 Respective acid Acid conc. CO3 2- (rose) 10 g 4.947 g (NO3)2- (pink- rose) 10 g 75 ml 3N (HNO3) Cl- (brown) 10 g 44.8 ml 5N (HCl) acetate 13.49 ml Glacial acetic acid citrate 43.247 In 100 ml water IV. DISCUSSION Recovery of spent dry battery cells has dual benefits. It helps to get rid of the waste of hazardous materials and obtain valuable products of market value. The average quantity of the used dry battery cells in Egypt increases dramatically on basis of the increasing rate of the population development. In this context, studies carried out to recycle the dry battery cells have different issues and objectives. Some studies paid attention to the zinc content alone whereas others paid attention to iron discs. In some cases, agencies had their aim to recover black paste altogether with zinc metal. The present study has its aim to make use of all the contaminants of the dry cell battery in the country. The experimental program started by dismantling the spent cell with the help of a double toothed saw blade. Plate 1 shows a split dry cell. Table 1 shows the contents of the battery cell. XRD patterns given in Figs 2a,b confirms the presence of these components. Determination of carbon in the black paste was examined by heating the black paste at temperatures up to 1000°C. the initial weight loss taking place up to 400°C can be attributed to the loss of moisture content and volatile salts such as ammonium chloride and ammonia. The slight increase in weight loss taking place within the temperature range 400-500°C is assigned to the escape of zinc chloride. The drastic increase in weight loss at 600°C is due to the oxidation of the available carbon in the black paste to carbon oxides(mono and dioxide) 2C + O2 2 CO ……………..(1) 2CO + O2 2CO2 ………….…(2) . The humidity detected in the cell upon cutting finds support from the fact that the chemical reactions taking place during discharging the battery generate water as follows: . Zn + NH4Cl ZnCl + NH4 + ……….(3) NH4 + NH3 + H+ ……….....…(4) 2H+ H2 + 2 e …………..…(5) 2H + MnO2 H2O + MnO .……….(6) and the overall reaction is: Zn + NH4Cl +MnO2 ZnCl + MnO + H2O +2e ...(7) The moisture content amounts to about 7.2% in the unused cells. Zinc chloride and ammonia primary used in the manufacture of the dry cells. During discharging of the battery, excessive quantity of water generated and dissolves more zinc chloride. This explains why the total weight of the water soluble salts in the spent battery(22.5 %) is much higher as compared to the new cell (7.2%). Results given in Fig. 5, is in a good agreement with the solubility of zinc chloride in cold water (432g/100g water) and hot water (635g/100 g water) [28] The particle size distribution analysis of the black paste given in Fig.6 shows that the finer particle size of <60 um helps to enhance the oxidation-reduction reactions (Ox-Re) to take place during the battery discharge at a high performance. This imparts a convenient duty of the battery. On the contrary, if the black paste has a larger grain size, it would decrease the efficiency of the Ox-Re) and the battery duty as well.
  • 6. International Journal of Technical Research and Applications e-ISSN: 2320-8163, www.ijtra.com Volume 3, Issue 1 (Jan-Feb 2015), PP. 25-30 30 | P a g e Leaching of zinc in different mineral acids (sulfuric, nitric and HCl ) showed that the process is time dependent particularly within the first 180 minutes. This phenomenon is ascribed to the passivity action of the generated hydrogen gas evolving during acid attack. Also the more concentrated acid has the same effect. Dilute acids helps less quantity of hydrogen gas to build a gas barrier on the zinc surface. The same explanation would be applied to the acid leaching of manganese. Results of fig. 9 confirm this model. The effect of particle size of the paste on the extent of acid leaching of manganese imparts that the surface area of the fine particles are much higher than coarse particles. In other words the surface subjected to acid attack is much more available with fine particles as compared to the coarser one. SEM image shows that the average grain size of the nanoparticles, obtained in this work, amounts to nearly 10-30um. REFERENCES [1] C. Nicolae, Rom. RO , 90 (1988), p. 70. [2] C. Shaoguo, “Comprehensive Utilization of Spent Dry Cells,” Huaxue Shijie, 26 (11) (1985), pp. 427–428 [3] W. Lindermann et al., “Batenus Process for Recycling Battery Waste” (Paper presented at the 24th Annual Hydrometall. Mtg., Canada, 1994). [4] T. Zhuqian and M. Guanggui, “Recovery of Manganese Dioxide and Zinc from Spent Dry-Cell Batteries,” Faming Zhuanli Shenqing Gongkai Shuomingshu CN 87, 102 (1988), p. 8. [5] T. Toita et al., “Treatment and Resource Recovery of Used Dry Cell Batteries,” Sumitomo Jukikai Giho, 36 (1988), p. 108. [6] R. Heng, W. Koch, and H. Pietsh, “Recycling of Spent Batteries,” Ger. Offen. DE 3,709,967 (1987). [7] M. Nanjo, “Alkali Manganese Batteries as New Zinc and Manganese Resources,” Prog. Batteries Sol. Cells, 7 (1988), pp. 303–310. [8] G. Hubwecher et al., “Process for Recovering Zinc and Manganese from Scrap Containing Zinc and Manganese Oxide,” Voes Alpine, patent EP0158627 (EUR) (1985). [9] Krueger, “Treatment of Zinc-Bearing Wastes and Residues by Vacuum Distillation,” Technische-Hochschule Achen, TIB/B90- 80824/XAB (1989). [10] M.A. Rabah and A.S. El-Sayed, “Recovery of Zinc and Some of Its Valuable Salts from Secondary Resources and Wastes,” Hydrometallurgy, 37 (1) (1995), pp. 23–32. [11] M. A. Rabah, M. A. Barakat, Y. Sh. Mahrous “Recovering metal values hydrometallurgically from spent dry battery cells” JOM, 1999, Volume 51, Issue 12, pp 41-43. [12] D. C. R. Espinosa, A. M. Bernardes, and J. A. S. Tenório, “An overview on the current processes for the recycling of batteries,” Journal of Power Sources, vol. 135, no. 1-2, pp. 311–319, 2004. [13] W. 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