Comparison of the CO₂ Balance in Electroslag Reduction of Cadmium with Pyrometallurgical and Hydrometallurgical Recovery Methods

This study presents a carbon footprint assessment of a novel electroslag method for cadmium (Cd) recovery from spent nickel–cadmium (Ni-Cd) batteries in comparison with the carbon footprints of pyrometallurgical and hydrometallurgical cadmium recovery methods. A comparison of CO₂ emissions in three types of technological processes during the recovery of 1 kg of cadmium is carried out. Energy inputs and CO₂ emissions are calculated for the electroslag process and compared to conventional methods, such as pyrometallurgical and hydrometallurgical reduction methods. The electroslag process eliminates cadmium vaporization by using molten KCl–NaCl flux and carbon under electromagnetic stirring. Cadmium reduction occurs under a layer of flux, which prevents the contact of the reduced cadmium with the atmosphere. The electroslag process temperature is limited to 700 °C, which is lower than the boiling point of cadmium (767 °C). The electroslag remelting process uses molten KCl–NaCl flux and carbon as a reductant under electrovortex flow stirring. The pyrometallurgical method for extracting cadmium from nickel–cadmium batteries is based on the reduction of cadmium with carbon at high temperatures. In the pyrometallurgical process, coal (anthracite) is used as the carbonaceous material, which can extract 99.92% of cadmium at 900 °C. Cadmium is separated using a vacuum at temperatures ranging from 800 °C to 950 °C for several hours. Hydrometallurgy is a metal extraction process involving chemical reactions that occur in organic or aqueous solutions at low temperatures. The hydrometallurgical process involves a series of acid or alkaline leaches, followed by separation and purification methods such as absorption, cementation, ion exchange, and solvent extraction to separate and concentrate metals from leach solutions.