Waste Zinc–Carbon Battery Recycling: Focus on Total Material Recovery

Currently, less attention is paid to zinc–carbon batteries, although they are still widely used and are among the major types of batteries collected and recycled. The recycling technologies currently in use do not allow the complete recovery of resources, are not self-sufficient and require additional financing. Therefore, this paper aims to study the possibility of complete recycling of waste zinc–carbon batteries and to suggest the practical use of the final products generated in the recycling process. The possibility of complex processing of spent zinc–carbon batteries using mechanical separation and processing of the battery’s components (steel case, zinc electrode, graphite electrode, polypropylene and paper insulators) is justified. The separation of spent electrolytes from other components of batteries with hydrochloric acid was studied. It was shown that the extraction of Zn2+ and NH4+ cations takes place following the addition of an equivalent amount of Na3PO4 solution and water-insoluble NH4ZnPO4 salt sedimentation. Waste agglomerate (mixture of MnO2, MnO(OH), and graphite) was regenerated to its initial composition (MnO2, graphite) at a temperature of 300–325 °C; manganese (III) hydroxide was oxidized to manganese (IV) dioxide. Thermal destruction of polypropylene and paper insulators with additional introduction of polyethylene into the primary mixture produced pyrolysis liquid, pyrocarbon and pyrolysis gas as products. The practical use of the products obtained and compliance with the environmental requirements of the suggested method of waste batteries recycling were shown.