Battery Black Mass
Recovery Plant
Analyzing and optimizing residence time, pH sensitivity, and sequential solvent extraction to maximize leaching efficiency for Shiva Engineering.
Client
Shiva Engineering
Industry
Specialty Chemical / Recycling
Process
Leaching & Extraction
Completed
May 2025
Project Overview
ChemKlub India undertook a comprehensive dynamic simulation study for a Battery Black Mass recovery project. The primary focus of this simulation was to analyze and optimize the residence time within the settler mixer, which is critical for enhancing leaching efficiency and downstream separation performance.
The simulation was carried out using advanced dynamic modeling tools to reflect real-time variations and process behaviors across different unit operations, including pH adjustment, intermediate reaction impurity removal, and sequential solvent extraction.
Process Highlights
Leaching Process
15% S/L Ratio at 80°C
Impurity Removal
Na₂CO₃ & H₂O₂ (pH 4-5)
Sequential Extraction
Targeting Li, Co, Mn, and Ni
Simulation Methodology
A two-step approach transitioning from steady-state validation to advanced real-time transient analysis.
Steady-State
Developing the complete process flowsheet in Aspen to validate mass balance, reaction conversions, and operating conditions.
Parameters
Fixing critical design parameters including flowrates, concentrations, and baseline residence times before transitioning.
Dynamics
Exporting steady-state results to Aspen HYSYS Dynamics to introduce control logics, PID controllers, and feed disturbances.
Output
Extracting residence time distribution curves, transient concentration profiles, and real-time temperature and pH variations.
Key Considerations in Process Design
The extraction process involves delicate chemical balancing. Our simulation guarantees process viability across the entire reaction chain.
Primary Objective
Optimize Residence Time
Temperature & pH Sensitivity
Mapping precise limits at every stage to prevent chemical degradation.
Sequential Extraction Efficiency
Optimizing conditions for targeted metal separation (Mn, Co, Ni, Li).
Residence Time Criticality
Securing exact durations in leach and intermediate reactors for reaction completion.
Mixing Dynamics
Analyzing dynamic behavior of mixing and separation to prevent losses of critical elements.
Crystallization Parameters
Controlling crystallization and drying parameters for product quality and moisture control.
Impurity Handling
Defining Na₂CO₃ and H₂O₂ interactions to remove impurities while preserving Li, Co, Mn, and Ni.
Process Challenges & Validation
Residence Time Under Variable Inflow
The settler mixers and reactors face constant variable inflow conditions. If residence time drops below required thresholds, incomplete leaching and significant metal losses occur.
Simulation Impact
By studying transient concentration profiles, the dynamic simulation establishes robust control logic ensuring constant residence time regardless of upstream feed disturbances.
Temperature Swings & Inefficiencies
Temperature swings and mixing inefficiencies critically disrupt the highly sensitive pH levels (pH 2.0 to pH 11-12) required for the sequential solvent extraction of valuable metals.
Simulation Impact
The real-time temperature and pH variation analysis identifies mixing dead-zones, enabling adjustments to agitation rates (70-90 RPM) and precise control of external heating or acid addition.
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