Selective Precipitation of Rare Earth Double Sulfate Salts from Industrial Ni–MH Battery Leachates: Impact of Downstream Processing on Product Quality

This work focuses on the recovery of rare earth elements (REEs = La, Ce, Nd, Pr) from spent nickel–metal hydride batteries by hydrometallurgical processing. The REEs were precipitated in the form of sodium-lanthanide double sulfate salts by adding Na2SO4 to a leach liquor prepared from industrially processed spent batteries. The objectives were to better understand the parameters driving the purity of the product and to identify the phases involved, as well as their crystallographic structure. The methodology included experiments performed in a 2 L reactor, thermodynamic calculations and product characterization. We confirmed that high REE precipitation yields (>95%) can be achieved under a wide range of hydrodynamic conditions. Furthermore, we demonstrated and quantified how appropriately washing the product allows for a significant reduction in nickel losses while maintaining control over REE product purity. Finally, using X-ray Diffraction analyses, it was established that REEs form a solid solution with a chemical formula (Na0.9K0.1)(La0.65Ce0.24Pr0.04Nd0.07)(SO4)2·H2O, which has not been reported so far.