A process flow sheet has been developed to produce cobalt metal and Electrolytic Manganese Dioxide (EMD) from Cobalt-Manganese Bromide (CMB) spent catalyst sludge. The Co-Mn sludge was leached in sulphuric acid media followed by the removal of organic matter from the leach liquor through adsorption by activated charcoal. Co-Mn separation was carried out by precipitating cobalt as mixed cobalt sulphide. The cobalt mixed sulphide was roasted and then leached in sulphuric acid to produce cobalt sulphate solution. Co metal and EMD were electrodeposited from their respective sulphate solutions. The optimal conditions during sludge leaching, Co-Mn separation, roasting of Co mixed sulphide, dissolution of the roasted material, electrodeposition of Co metal and EMD have been studied. The EMD was characterized for its suitability for the use in batteries and a tentative flow sheet for processing Co-Mn sludge is presented. (C) 2015 Elsevier B.V. All rights reserved.
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