Process Route & System Overview

A spent lead-acid battery recycling line typically consists of crushing & sorting, lead paste pre-desulfurization, smelting & refining, and EHS systems. Through systematic design addressing front-end material conditions, sulfur-containing lead paste characteristics, and emission boundaries, we achieve a complete production line from incoming batteries to qualified lead ingots and compliant waste emissions.

The lead-acid battery crushing & sorting system targets "high recovery rate, low entrainment, stable continuous operation." The process is typically organized as enclosed feeding - controlled crushing - multi-stage sorting - material routing. After feeding and pre-treatment, spent batteries enter the crushing unit with enclosed and interlocked controls to reduce acid mist and lead dust escape risks. The crushed mixture enters the sorting section where screening/washing (or hydraulic sorting) achieves initial separation of electrolyte and fine particles, followed by multi-stage routing and purification of lead paste, lead grids, plastics, and separators/impurities based on physical property differences, providing cleaner, more uniform feedstock for subsequent smelting and resource utilization.

The lead paste pre-desulfurization system addresses sulfur-containing lead paste feedstock using ammonium or sodium-based pre-desulfurization routes to transfer sulfate components into the solution phase, achieving "solid-liquid separation - solution purification - sulfate crystallization recovery" closed-loop processing. Pre-desulfurized lead paste proceeds to subsequent smelting/refining or regeneration stages, while the solution side enters sulfate solution purification and crystallization units to recover storable, usable solid by-products, with mother liquor recycled as needed or sent to subsequent treatment systems.

The smelting and refining ingot casting system targets "stable production of qualified lead ingots," receiving pre-treated lead paste, lead grids, and other lead-containing materials. Through smelting - crude lead processing - refining and impurity removal - composition adjustment - ingot casting, metal recovery and product formation are achieved. Materials complete metal phase and slag phase separation in the smelting unit, crude lead enters the refining section for stepwise impurity removal with composition fine-tuning and temperature stabilization, finally cast into ingot form for convenient transportation and trade delivery.