jangyec

Sustainable Recycling of Lead Acid Batteries

Lead-Acid Battery Green Recycling 
 The equipment features a custom-designed configuration tailored to client specifications, integrated with an automated control system and centralized monitoring through a dedicated control room. Utilizing advanced human-machine interface technology, the system enables single-operator management via the master control terminal, ensuring both operational safety and full-process equipment functionality. This streamlined configuration requires only 3-5 personnel for complete production management. Following the crushing and sorting processes, materials including lead ingots, lead plates, high-density plastics, and low-density plastics are automatically sorted into designated collection zones for organized storage.
Smart Electrical Control
3. Dual-mode Operational Flexibility

Seamless manual/automatic mode switching with:

  • Priority override functionality
  • Fail-safe transition mechanism
  • Mode status indication system

2. Premium Control Infrastructure
Utilizes industrial-grade components from global leaders:

  • IPC (Industrial PC) systems
  • SCADA-based control architecture
  • PLC solutions (Siemens/Allen-Bradley equivalent)

Features intuitive HMI (Human-Machine Interface) with:
• Visualized process flow monitoring

• Touch-optimized control interface

• Multi-level access management




1. Integrated Intelligent Control System
A converged technological architecture incorporating:
• Process Automation Control
• Multi-sensor Network Integration
• Variable Frequency Drive Regulation
• Industrial-grade Communication Protocols

• Enterprise-level Computerized Management


Subsystems:
a) Smart Power Management System - Precision energy

     regulation
b) Centralized Information Hub - Real-time data

     orchestration & production optimization

4. IoT-enabled Remote Support Ecosystem
24/7 cloud-based service platform offering:
✓ Remote diagnostics & troubleshooting
✓ Predictive maintenance alerts
✓ Firmware OTA (Over-the-Air) updates
✓ Operational analytics reporting
Techinical Parameters
· Moisture content of lead paste <12%

· Total lead recovery rate ≥98%

· Plastic recycling rate ≥98%

A. Lead Paste Ammonium  Desulfurization System
Lead Paste Desulfurization 

This device is used for desulfurization treatment of lead paste separated from lead-acid batteries. The process includes:

The lead paste enters the pre desulfurization reaction tank A, and desulfurizer (ammonium bicarbonate) is added. At the same time, the mixed lead paste slurry in the tank is subjected to forced desulfurization before returning to the pre desulfurization tank. After the reaction is completed, a filter press is used for solid-liquid separation, and the filter cake (desulfurization lead paste) enters the smelting system; The filtrate (desulfurization filtrate A) enters filtrate tank A. The filtrate A is used as the reaction medium and enters the pre desulfurization reaction tank B. Lead paste and ammonium bicarbonate are added for desulfurization reaction, and the mixed lead paste slurry in the tank is subjected to forced desulfurization before returning to the pre desulfurization tank. After the reaction is completed, a filter press is used for solid-liquid separation, and the filter cake (desulfurization lead paste) enters the smelting system; Filtrate B (desulfurization filtrate B) enters filtrate tank B. The filtrate B (ammonium sulfate) enters the ammonium sulfate purification system.

· Sulfur content of lead paste after desulfurization < 0.5%

· Moisture content of lead paste after pressure filtration<12%

· Control system: adopting PLC centralized control

Ammonia Desulfurization
Techinical Parameters
· Moisture content of lead paste after pressure filtration<12%

· Control system: adopting PLC centralized control

B. Lead Paste Sodium Desulfurization System

 This device is designed for desulfurization treatment of lead sludge obtained from the crushing and separation of lead-acid batteries. The process includes:

Lead mud enters the desulfurization tank, reacts with desulfurizer (sodium carbonate), and is thoroughly stirred. At the same time, the mixed lead paste slurry in the tank is subjected to forced desulfurization before returning to the pre desulfurization tank. After the reaction is completed, a filter press is used for solid-liquid separation, and the filter cake (desulfurization lead paste) enters the smelting system; The filtrate (sodium carbonate) enters the filtrate tank.

· Sulfur content of lead paste after desulfurization < 0.5%

Sodium Desulfurization
Techinical Parameters
1.The pre desulfurized filtrate is sent to the purified raw material storage tank.
2.The PH value of the filtrate is adjusted in the reaction tank, and purification reagent is added.
3.After passing the inspection, store in the liquid storage tank.

A.Ammonium sulfate solution:25-35%, The heavy metal content in the treated solution is less than 10PPM.

B.Sodium sulfate solution: 16-28%, with a heavy metal content of less than 10 PPM in the treated solution


Technical Parameters
Process Flow
C.Sulfate Solution Purification System
Evolutionary treatment of heavy metal ions and other impurities in the sulfate solution generated by pre desulfurization.  

Purification Treatment Process
Evaporating Crystallization
Drying Process
The purified sulfate solution is processed by MVR to generate sulfate products.
The condensed water generated by M VR is returned to the desulfurization process for recycling or (and) discharged after being treated and qualified.

After complete dehydration through drying equipment, high-purity sulfate products are obtained and sold.


D. Sulfate crystallization drying equipment
MVR 
After the mixture enters the high-temperature melting furnace, the reduced lead enters the ingot hopper, and the lead slag is discharged into the lead slag hopper. The flue gas generated during the smelting process is treated and discharged in compliance with standards. The equipment includes precise proportioning, automatic feeding, combustion system, furnace body, cooling system, and exhaust gas dust removal and desulfurization treatment.

Lead Paste Converter Melting System
The recycling process for fragmented and pre-sorted plastics involves sequential procedures including primary sorting, chromatic separation, dehydration, and pelletization. This comprehensive system incorporates specialized equipment: a plastic shredder, high-pressure rinsing unit, centrifugal dewatering dryer, optical color sorter, and compounding extruder.

Plastic Cleaning & Color Separation System
Smelting system
Lead Ingot Casting Machine
The production process involves two sequential phases: metallurgical refining and automated ingot formation. Crude lead undergoes purification to produce refined lead (primarily lead alloy), which is subsequently cast into standardized ingots through precision temperature-controlled molds. The system incorporates an intelligent stacking mechanism capable of processing 20-30 MT/hour, with product differentiation between standard-grade (ASTM B29-12) and smart-grade (IoT-enabled) specifications.

Servo automatic pouring device, linear ingot casting machine, ingot feeding and arranging machine, palletizing robot, ingot stacking conveyor, packaging machine, weighing device, labeling and labeling. Program control, high degree of automation, saving labor.

The star shaped roller pouring device, linear ingot casting machine, ingot feeding and discharging machine, palletizing manipulator, ingot stacking conveyor, packaging, weighing, marking, and labeling processes are completed manually.

B. Intelligent System
A. Standard System
Exhaust gas treatment system
Handle the exhaust gas, lead dust, ash, etc. generated during the lead smelting process to avoid environmental pollution.

 This equipment mainly converts lead liquid into lead sheets which can be classified into several types according to the process through a cylindrical film making machine, and then goes through a lifting device, a flat sheet device, enters a sheet arranging device, and then enters other processes.
Capacity: 400 pieces/hour~480 pieces/hour

Dimensions: Length x Width x Height = 12000mm X 3500mm X5400mm 

Rated Power: 27kw

Lead Cathode Sheet Manufacturing Unit
Lead Anode Disk Ingot Casting Unit
Including three models: 16 model, 18 model, and 20 model.
This device mainly uses lead Liquid to pass through the lead anode ingot linkage line, pass through the mold, and cool down to become standard lead anode plates. Then, it is transported to the plate conveyor through automatic fishing and flat plate devices.
Capacity: 200 pieces/hour~280 pieces/hour
Dimensions: Disc Diameter approximately 6070mm~7800mm
Rated Power: 30-32kw