Ultrasound-assisted efficient and convenient method of extracting valuable metals (Ni, Co, and Cd) from waste Ni-Cd batteries using DL-malic acid.

Recycling waste Ni-Cd batteries has received much attention recently because of the serious environmental pollution they cause and to avoid the dissipation of valuable metals. Despite significant research, it is still difficult to efficiently recycle valuable and hazardous metals from waste Ni-Cd batteries in an economical and environmentally friendly manner. This study employed a novel process utilizing ultrasound-assisted leaching to recover Ni, Cd, and Co from waste nickel-cadmium (Ni-Cd) batteries. Organic DL-malic acid served as the leaching agent and H2O2 was employed as an oxidizing agent. The effects of various factors on the recovery efficiency of Ni, Cd, and Co, such as leaching temperature, time, DL-malic acid concentration, pulp density, H2O2 concentration, and ultrasound frequency, were also examined. To predict the chemical compounds present before and after the recycling experiments, the solid residues from the metal extraction were analyzed using XRD, XPS, FE-SEM, and EDS element mapping. Concurrently, ICP-OES was utilized to determine the metal content in the leachate. Under optimized conditions of 90 °C, 90 min, 2M DL-malic acid, 160 mL/g pulp density, and 20% ultrasound frequency, over 83% of Ni, 94% of Cd, and 98% of Co were effectively leached from the waste Ni-Cd battery powder. The leaching kinetics of Ni, Cd, and Co followed the surface chemical reaction control model. The activation energies (Ea) for Ni, Cd, and Co leaching were 21.34, 20.47, and 18.38 kJ/mol, respectively. The findings suggest that ultrasound-assisted leaching is an efficient, cost-effective, environmentally friendly, and sustainable alternative for extracting precious and hazardous metals from waste Ni-Cd batteries. Additionally, it reduces industrial chemical usage and enhances waste management sustainability.