By developing technologies, spent lithium-ion batteries (LIBs) are considered a great source of nickel-cobalt ions to fabricate metal sulfide nanoparticles. However, the presence of unnecessary ions such as manganese and lithium may hamper the formation of pure metal sulfide nanostructures where the utilization of proper ligand(s) can be very critical. For this reason, the present study initially introduces a promising and cost-effective acidic leaching followed by precipitation and thermal treatment (~250 °C, 1 h) processes to fabricate pure NiS nanopowders from the LIBs, while considering potassium amyl xanthate as the precipitating agent. The produced nanoparticle’s size and structure were characterized by commonly used and advanced analytical techniques such as X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and photon correlation spectroscopy (PCS), and inductively coupled plasma optical emission spectrometry (ICP-OES). The elemental distributions and functional groups were analyzed through energy dispersive X-ray spectroscopy (EDS) and Fourier-transform infrared spectroscopy (FTIR) methods. The characteristic analyses of the spherical-like NiS particles showed a mean particle size of 61 ± 2 nm (by TEM) and 64 nm (through the PCS method) with high purities approved via XRD and EDS analyses. Moreover, comparing the obtained XRD data with the standard ones showed a perfect match with the hexagonal structure of the NiS phase. We finally concluded that such a presented approach is very practical and efficient for converting the LIBs to an extremely valuable product. Future studies are suggested for the fundamental conceptualization of the processes.

In this paper, mechanical stirring and ultrasonic treatment are used to separate graphite electrode materials from copper foils in recycling spent lithium-ion batteries (LIBs). Firstly, the effects of ultrasonic power (60–180 W), ultrasonic time (1–8 min), stirring speed (420–2000 rpm), and stirring time (1–8 min) on the abscission rate of active material on copper foil were studied. It was found that the peeling-off ratio of electrode material under ultrasonic treatment was 91.34% compared with stirring treatment (84.22%). The removal of electrode material from copper foil during stirring was mainly through mechanical scrubbing. As a comparison, the generation of the microjets induced by ultrasound, the local high-temperature and high-pressure environment, and the free radicals during ultrasonic treatment are the key factors to further improve electrode material removal efficiency. An integrated ultrasound-mechanical stirrer technique can achieve a high-efficient separation performance (approximately 100% peeling-off ratio) of anode electrode materials from copper foils. The effects of mechanical stirring speed, temperature, and treatment time on the peeling-off ratios of the ultrasound-mechanical stirrer-assisted system were investigated. Finally, the results of XRF (X-ray fluorescence spectrometer), XRD (X-ray diffraction), and SEM-EDS (scanning electron microscopy coupled with energy dispersive X-ray spectroscopy) showed that the as-separated graphite electrode material had high purity and contained almost no copper foil impurities. Numerical simulation analyses briefly showed that the difference between pressure and ultrasonic temperature changes in the boundary between different anode layers (graphite on copper foil in aqueous solution) was the main effective factor in the considerable separation of graphite from copper anode foil under ultrasonic-assisted delamination.

In open-pit mines, the blast operation should be effectively optimized, leading to minimization of production costs through the application of specific technical specifications. However, there is inadequate information in the literature to link blasting to comminution stages. To this end, the effective parameters for the performance of mining unit operations were scrutinized in this work. In this regard, the rock fragmentation distribution (RFD) caused by blasting was considered the main determinative criterion for providing the optimum conditions for the blasting operation at Sarcheshmeh copper mine. By carrying out a statistical analysis of the experimental data, operational parameters affecting the blasting were optimized. The relationship between parameters was obtained using the technique of regression and in accordance with the evaluation criterion under which correlation coefficient (R²) was used to determine the best fitting model. A high correlation coefficient of the loading cycle of the machine’s bucket $\left({\mathrm{C}}_{\mathrm{l}}\right)$ with the independent variables showed that the C₁ was more affected by the RFD, as well as the dimensions of the blast block. Because of the wide variations in the nature and structure of rock mass in different mines, in each case, sufficient data should be collected, and these relationships should be analyzed statistically for each individual mine showing wide ranges of fractures and cracks. Therefore, due to these wide variations of ore characteristics, with the current data it seems very difficult to quickly find a significant operational relationship between downstream processes such as crushing efficiency and blasting operations. Therefore, the focus of this research was limited to the effective parameters for blast efficiency. According to the analysis of the data obtained from 20 blasts under different operating conditions, the diameter of the hole was 241.3 mm (such as blast number 20), the ratio of length to width of the explosive block was about 6 (average blasts with high fragmentation efficiency), and the best index of mining operations was 0.22 (such as blast number 20).

The dominant challenge of current copper beneficiation plants is the low recoverability of oxide copper-bearing minerals associated with sulfide type ones. Furthermore, applying commonly used conventional methodologies does not allow the interactional effects of critical parameters in the flotation processes to be investigated, which is mostly overlooked in the literature. To tackle this issue, the present paper aimed at characterizing the behavior of five key effective factors and their interactions in a sulfidized copper ore. In this context, dosage of collector (sodium di-ethydithiophosphate, 60–100 g/t), depressant (sodium silicate, 80–120 g/t) and frother (methyl isobutyl carbinol (MIBC), 6–10 g/t), pulp pH (7–11) and agitation rate (900–1300 rpm) were examined and statistically analyzed using response surface methodology. Flotation experiments were conducted in a Denver type agitated flotation cell at the rougher stage. The experimental results showed that increasing the pH (from 8 to 10) at low agitation rate (1000 rpm) enhanced the recovery from 80.36% to 85.22%, while at high agitation rate (1200 rpm), a slight declination occurred in the recovery. Meanwhile, increasing the collector dosage at a lower frother value (7 g/t), caused a reduction of about 4.44% in copper recovery owing to the interactions between factors, whereas at a higher frother level (9 g/t), the recovery was almost unchanged. The optimization process was also performed using the goal function approach, and maximum copper recovery of 92.75% was obtained using ~70 g/t collector, 110 g/t depressant, 7 g/t frother, pulp pH of 10 and 1000 rpm agitation rate.