Battery crusher battery breaker for battery recycling

Unionsum can offer tailor-made, environmentally sound and optimized solutions for battery recycling projects, which includes from battery breaking and separation, desulfurization, Lead smelting, Lead refining, and Lead ingot casting.

The Lead battery recycling system is a full-automatic standard and Environmental Friendly system. Pb ingot with purity 99.95% or 99.99% can both be produced with different process.

1. Preliminary crushing

As the spent lead-acid battery contains 20±5% acid, we designed the preliminary crusher and drum screen to release the acid firstly. 

A grabbing crane will pick up the spent battery from storage to the preliminary crusher through vibrating feeder. The crushed battery will be discharged to the screw drum separator with screen. The H2SO4 acid with some lead paste will be thrown away from the drum and go to waste acid settling tank, and then be separated by filter press. The lead paste will directly go to de-sulphurization process and the waste acid will be treated by professional acid plant. The rest of crushed batteries will be transferred to the secondary crusher through belt conveyor with VSD motor. 

2. Secondary Crushing

On the head of belt conveyor, there is an Electromagnetic Separator to remove the magnetic metal, which can protect the crusher hammer and guarantee the product purity. Then the fragment will be discharged through the crusher screen to primary vibrating screen to be washed and separated.

3. Separation

There are 6 sets of 18 nozzles in the vibrating screen separator spray the water to the battery fragment. The lead paste(undersize) pass through the screento the sedimentation boat, and then agglomerate by flocculants and settle down at the bottom. Then the lead paste is collected by rake and transported to stirring settling tank. When the lead paste density in the tank satisfies the setting requirement, it will be pumped to filter press to dry the lead paste.

The oversize containing PP/heavy plastic and lead grid, will going to the 1# hydro-separator. PP floating on water surface, will be paddle to the PP storage by 1# PP screw conveyor. The others part will settle down and transported to 2# hydro-separator by 1# lead grid screw conveyor.

In the 2# hydro-separator, the lead grid will settle down again and transported to the grid storage by 2# lead grid screw conveyor, the heavy plastictogether with some heavy plastic from 1# hydro-separator will float to the second vibrating screen by contra water flow mixing with air. The undersize lead mud will come back to lead sedimentation boat again. The oversize heavy plastic and some PP will be transported to the settling tank to separate by flotation method again.

The whole plant water system is a closed circuit with pH meter and discharging control system.

Through the battery crushing and separation process, we can get lead paste, grid, PP/PVC and heavy plastic separated. And we can guarantee the whole battery recycling process has no pollution to atmosphere.

4. Lead Paste Desulphurization

As the environmental protection and energy saving demands, we convert the Lead paste to PbCO3 before smelting. The reaction equation is:

PbSO4+Na2CO3=PbCO3+Na2SO4

The Na2SO4 in the solution will be purified and recovered as by product, and the waste water will be recycled.

5. Na2SO4Purification and Crystallization

We use the Fe-C micro electrolyte to purify the Na2SO4 solution and remove heavy metal. This purification system can be tolerant to different heavy metal content, and can treat the high content solution. The heavy metal content after Fe-C micro electrolyte purification is ≤10ppm.

Na2SO4 •10H2O will go to the drying oven for further drying, and become Na2SO4 crystal.

6. Acid mist Collection and Treatment

The acid mist discharging site are crushing room, hydro-separator, lead mud conveyor end, lead paste stirring tank top, filter press room. There are acid mist collection devices at these locations. The acid mist will be collected and then neutralized in the scrubber.

7. Process water treatment system

The water in sedimentation boat is a closed circuit, with pH meter and discharging control. 

8. Desulphurized lead paste smelting

The de-sulphurized lead paste with certain amount of lime, silica sand, Fe powder, will be pelletized, dried, and then fed into the rotary furnace or blast furnace. PbCO3, PbO2, PbO will be decomposed and reduced in the rotary furnace or blast furnace by natural gas or other reductant. The product is lead bullion, it will be fire-refining in lead pot. The off-gas will go to surface cooler, dust collector. The dust will be back to pelletize.

The process has following advantages:

Short process circuit and high lead recovery.

High heat utilization rate, large lead paste capacity, low operation cost, especially the blast furnace.

9. Lead bullion fire-refining

Lead bullion will be fire-refining in the lead pot to remove the impurity. Then The 99.9% pure lead liquid will be pump to casting machine.

10. Lead Grid Fire-Refining In Lead Pot

The lead grid will be fire-refining in lead pot also. We will add Ca, or Sb to adjust the constituent and then to cast it.

11. Lead ingot casting

The lead alloy and pure lead usually will be cast to lead ingot of 24kg, 38kg or 48kg.

Unionsum can dispatch experienced engineers overseas to guide the installtion and commissioning work of the battery recycling work until the customer can produce the target product.

For Iran 100,000TPY battery recycling project:

Unionsum, a subsidiary of CRIMM, provides sustainable system solution for mining and

metallurgy industry, including engineering, procurement and construction, and offers a widerange of

scientific research and consultingservices.

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