# Patent

## Title
Method for implementing full cycle regeneration of waste lead acid batteries

## Abstract

A method for implementing full cycle regeneration of a waste lead acid battery is provided. The method includes the following steps. Step (1): the waste lead acid battery is smashed and separated so as to obtain grid lead, diachylon, plastic and waste electrolyte. Step (2): the obtained diachylon after being dried is positioned into an airtight reactor for desulphurization and deoxidation, wherein lead sulfate and the lead dioxide both in the diachylon react to obtain lead monoxide (PbO) and sulfur trioxide (SO3). Step (3): the obtained lead monoxide is reduced by solid phase electrolysis in a wet way so that the lead monoxide is reduced into sponge lead.

## Background
FIELD OF THE INVENTION
This invention relates to a method for regenerating waste lead acid batteries. In particular, it relates to a regeneration method for waste lead acid batteries at a large industrial scale with such characteristics as low energy consumption, low cost, high-recovery rate, etc. This method implements full cycle regeneration of waste lead acid batteries and meet with the requirement of environment protection.
BACKGROUND OF THE INVENTION
The lead acid battery is widely used in many fields for power storage, such as automobile, telecommunication, railroad, ships, electric vehicles, wind power, solar energy, etc. as a consumptive-material product. It includes a pole plate made up of alloy lead; diachylon consisting of lead sulfate, lead dioxide and lead monoxide; electrolyte containing mainly diluted sulfuric acid; plastic battery enclosure, upper cover and separator, etc. Its annual consumption is huge. If every element of the waste lead acid battery can be substantially recovered for reuse, especially in the production of lead acid batteries so as to implement full cycle regeneration of the waste lead acid battery, the economic benefit is very significant and there is a great social benefit from the associated energy-saving, consumption reducing and environment protection.
However, the known conventional regeneration method of waste lead acid batteries not only wastes a large amount of resource and energy, but also merely recovers parts with high commercial value, such as pole plate and diachylon as well as plastic enclosure from the waste battery. Only simple treatment or even no treatment is made for the other parts of the waste battery, such as plastic separator and electrolyte, and some other parts are simply thrown away without any treatment. Thus, such method is unable to implement full cycle regeneration of the waste lead acid battery, leading to serious problems of environment pollution: the insufficiently treated waste batteries are themselves a serious pollution source and cause the primary pollution; then, the flaws of the regeneration process can cause the secondary pollution. As a result, the waste lead acid battery has become a difficult common environment protection problem for the world.
At present, the conventional regeneration method of waste lead acid batteries includes mainly pyrometallurgical reduction method and electrolysis reduction technology (or wet-treatment method) as detailed below:
Pyrometallurgical Reduction Process
Pyrometallurgical reduction process is a regeneration process to recover diachylon. It has the following shortcomings:
(1) During the pyrometallurgical reduction process, it will cause the secondary pollution due to the reducing agent added which produces a lot of residue. The general pyrometallurgical residue rate of non-converted desulphurization of is 25% ̃30%, and the residue rate of converted desulphurization is 10% ̃15%. Both type residues are the waste, which cannot be recovered by the system.
(2) During the pyrometallurgical reduction process, it cannot be avoided to produce a lot of high temperature CO2, nitride gas and minim PbO, SO2, dioxin gas to pollute the environment. Although oxygen-enriching, most-environment friendly liquefied gas or natural gas are used as fuel, and the best dust collection unit is selected, it cannot be avoided to cause the problem to pollute air due to PbO and traces of PbSO4 produced during the direct high-temperature reduction process.
(3) The metal recovery rate of the pyrometallurgical reduction process is low. The lead retained in the residue is as high as 1% ̃2% for pyrometallurgical process in general. It can reach 3% ̃8% in worst scenarios. As the residue contains more metal, resource is wasted and the secondary pollution will be caused.
For both the pyrometallurgical reduction process and electrolytic reduction process, it is often necessary to subject the lead sulfate (PbSO4) of the diachylon in waste batteries to a desulphurization process. At present, there are two commonly-used desulphurization methods, as follows:
(I) Raw Material Mixing High-Temperature Melting Method
At present, in the domestic market, more than 90% of smelting method to recover waste battery is using a direct coal-fired reverberatory furnace. Using this method, it is not necessary to separate metal lead and diachylon from the waste battery plate, and the diachylon is mixed directly with scrap iron, sodium carbonate, reducing coal, etc. to have a substitution reaction under a high-temperature condition. As there is no smashing and separating process for the pole plate of the waster battery, it is not an ideal condition for the diachylon in the pole plate to contact with a lead sulfate state, added in with scrap iron, sodium carbonate, reducing coal, etc. Under a high-temperature condition with direct coal burning (over 1000° C.), the lead sulfate part is separated out to produce sulfur trioxide (SO3) gas. A part of PbSO4 and scrap iron is reduced into metal lead in substitution reaction and produces a lot of iron sulfide residue. As a large quantity of air enters during combustion process, SO3 gas contents are low. It is difficult to be recovered such low concentrations of SO3 to be used in manufacturing sulfuric acid and can only be discharged as a waste. In addition, as there is no special desulphurization neutralization unit, the waste SO3 gas will cause the secondary pollution. This method produces the waste residue at a rate of 25 ̃30% of the initial material, further causing a serious pollution of solid waste. Furthermore, the production cost is high and resource waste is serious due consumption of a large quantity of scrap iron converted into waste residue.
(II) Smashing Pre-Treatment Substitution Method of Waste Battery at a Normal Temperature
This method is to make a smashing pre-treatment to waste battery to separate metal lead and oxide diachylon. The PbSO4 in diachylon undergoes a substitution reaction at a normal temperature with Na2CO3 or NaOH added in. Its reaction is shown as follows:

PbSO4+Na2CO3═PbCO3+Na2SO4 

PbSO4+NaOH═PbO+Na2SO4 

The produced PbCO3 and PbO undergo a smelting reduction reaction in the converter. During the smelting process, no SO2 is produced. This method this is substantially free of SO2 pollution. But the method consumes a large quantity of expensive Na2CO3 or NaOH material to produce the low-value Na2SO4, which has little demand on the market. The cost of smelting recovery is high and obtained sodium sulfate cannot be reused in the battery manufacture.
Table 1 is an effect comparison of the above two types of desulphurization processes.













Process method











Smashing pre-treatment



Raw material mixing
substitution method of waste battery


Effect comparison
high-temperature melting method
at a normal temperature





Raw material
No smashing and separating
Smashing and separating equipment is


treatment state
equipment
needed.


Consumable material
Scrap iron, sodium carbonate,
Sodium carbonate, reducing coal


of desulphurization
reducing coal


Gas produced
40-50% PbSO4 is dissociated to
Substitution at a normal temperature to



produce SO3, which is 50 KG/T lead.
produce gas. Infinitesimal residual



As a large quantity of air is insufflated
PbSO4 is smelted to produce SO2 gas



into direct combustion, SO3
at a high temperature.



concentration is low. It is difficult to
Oxygen-enriched fuel is adopted. The



be used. It is discharged after simple
waste gas reaches the discharge



treatment and does not reach the
standard after treatment. It is difficult



environment standard of discharge,
to reuse the waste heat.



causing serious pollution.


Residue produced
Residue 300 KG/T lead produced, no
Residue 100 KG/T lead produced, no



value in use and is handled as
value in use and is handled as



dangerous waste.
dangerous waste.


Cycle regeneration
Only recover metal lead, no
Only recover metal lead, to produce


effect
by-product produced, to produce a
200 KG Na2SO4/T lead, which can



large quantity of waste gas/residue,
only be sold as a by-product and has



which cannot be reused.
little demand on the market. The cost




is high.









The above two desulphurization processes adopt a substitution reaction principle, to use expensive sodium hydroxide, sodium carbonate, scrap iron, etc. to substitute low-value by-product of sodium sulfate into low-value by-product, sodium sulfate, or dangerous waste, residue, which are difficult to be reused. The material cost to be used as substitution amounts to more than 50% of the manufacture cost.
The current electrolysis reduction technology can effectively solve this problem: the reducing agent is added to produce a large quantity of residue and causes the secondary pollution during the pyrometallurgical process. It can also solve the pollution problem of producing a large quantity of high-temperature CO2, nitride gas and minim PbO, SO2, dioxin gas, etc., which cannot be avoided during the pyrometallurgical process. The electrolysis reduction technology has a higher recovery rate of metal lead and less pollution compared to the pyrometallurgical reduction process method. At present, there are mainly two types of common electrolysis reduction technology. It is described as follows:
(I) Solid Phase Electrolysis Reduction Process in a Wet Way
The main process flow is as follows: smashing and separating battery—coating plate manually with the diachylon consisting of PbSO4, PbO2 and PbO—solid phase electrolysis (NaOH electrolyte)—refining (in solid phase electrolysis, Na2SO4 is obtained)
There is no desulphurization process during the above-mentioned solid phase electrolysis reduction process. The separated diachylon after directly coating plate is electrolyzed in NaOH. During the electrolysis process, a large quantity of NaOH is consumed. NaOH produces Pb and Na2SO4 with PbSO4 in diachylon. As there are many kinds of metal oxide, such as PbSO4, PbO2, PbO, etc. in diachylon, Na2SO4 obtained during the electrolysis process electrolyte has a greater effect on the electrolyte. And electrolyte cycle system is not adopted to separate the electrolyte, causing unstable factors and higher power consumption.
(II) Electrolytic Deposition Process
The difference point to the above-mentioned solid phase electrolysis reduction process is that electrolysis deposition includes a desulphurization process. Its main flow is: smashing and separating battery—the diachylon consisting of PbSO4, PbO2 and PbO is desulphurized and converted with Na2CO3 or NaOH—thermal decomposition is used to disassociate PbO2 into PbO—silicofluoric acid is used to leach-out PbO as lead ion—deposition electrolysis reduction.
The desulphurization process in the electrolysis deposition process adopts the above-mentioned smashing pre-treatment substitution method of waste battery at a normal temperature.
Table 2 is a comparison table for the above two electrolysis processes












Process
Solid phase electrolysis reduction
Electrolysis deposition process


technology
process in a wet way
in a wet way







Process
There are no desulphurization and lead
Material is sorted. Na2CO3 is used to


comparison
dioxide disassociation processes after
convert diachylon for desulphurization



raw material is sorted. Multi lead
conversion. Thermal decomposition is



compounds are directly under solid
used to disassociate PbO2 into PbO.



phase electrolysis.
Silicofluoric acid is used to leach out PbO




as lead ion - deposition electrolysis




reduction.


Desulphurization
During the electrolysis process, NaOH
Smashing pre-treatment method of


method
is used to substitute sulfur in PbSO4.
substitution at a normal temperature for




waste battery is adopted.


Desulphurization
NaOH is used to substitute and remove
Na2CO3 is used to substitute and remove


scheme
sulfur during the electrolysis process, to
sulfur. The cost is high. Na2SO4 treatment


comparison
obtain Na2SO4. The treatment and
and recovery is easier compared to the



recovery are difficult. The cost (cooling
solid phase electrolysis reduction process



electrolyte) is very high. Lead
(solid-liquid separation mode), but the cost



consumption/T is larger than 150 Kg
is very high. Lead consumption/T is larger



NaOH.
than 200 Kg Na2CO3.


Deoxidation
No disassociation PbO2
PbO2 is disassociated after substitution and


decomposition

removal of sulfur. One more process.


PbO2 affection
PbO2 occupies more than 40% of
Although PbO2 is disassociated, the anode


on electrolysis
electrolysis material and power
is easy to regenerate PbO2 during the



consumption is 40% more.
electrolysis process, which causes high




power consumption and unstable factor of




production.


PbSO4 affection
Electrolysis process continuously
PbSO4 is difficult to dissolve in the


on electrolysis
produces Na2SO4 to cause element
silicofluoric acid. The desulphurization



change of the electrolyte and unstable
conversion is thorough, which affects



electrolysis condition.
direct metal recovery rate.


Electrolysis
24 hours, high power consumption,
72~96 hours, high power consumption,


cycle
1000 KW/T sponge lead
1400 KW/T electrolysis lead


De-lead mode of
Sponge lead is formed. Na2SO4 is
Lead is sheet style, easy to fall off.


pole plate and
available, difficult to fall off.


coating plate


mode


Direct recovery
>85%
>88%, non-thorough conversion part of


(diachylon to

PbSO4 and PbO2, unable to be electrolyzed


sponge lead)

and leached out.


Product quality
Lead purity >99.95%
Lead purity >99.99%


By-product
Na2SO4 is less demanded on the market.
Na2SO4 is less demanded on the market.



The price is low. It is unable to be used
The price is low. It is unable to be used



battery manufacture in cycle.
battery manufacture in cycle.


Electrolyte
NaOH solution
Smell of silicofluoric acid is large.


Production cost
High, electrolysis is uneven. Only
Tiptop



small-scale production.









The electrolysis deposition process has been listed in Demonstration Catalogue for National Advanced Pollution Treatment Technology. Comparing with the current solid phase electrolysis reduction process, both processes have no waste to discharge out. They are favorable for environment protection, but there are still following shortcomings for the electrolysis deposition process in a wet way:

    
    
        (1) Electrolysis cycle time is longer than that of the solid phase electrolysis reduction process and power consumption is higher.
        (2) Desulphurization has to be very thorough. As lead sulfate is not dissolved in silicofluoric acid, desulphurization conversion rate is generally 97%. Therefore the cycle treatment quantity of leaching-out rate is increased.
        (3) PbO2 existing makes electrolysis deposition very unstable. In diachylon, PbO2 occupies 40% of the contents. Although thermal decomposition method is adopted to decompose into PbO, a certain quantity of PbO2 is still not decomposed. During electrolysis process, it is easy to make ion produce PbO2 precipitation, which affects power consumption and stability of the electrolysis deposition process.
        (4) Silicofluoric acid is used as electrolyte. The gas smell produced form silicofluoric acid is unpleasant.
        (5) Cost is too high.
        (6) There is still no way to implement full cycle regeneration of waste battery. It can only recover the diachylon from the waste battery in a form of meal lead to be recycled for producing lead acid battery. But the by-product Na2SO4 cannot be reused in battery manufacture.
    
    


DETAILED DESCRIPTION OF THE INVENTION
The purpose of this invention is to provide a process of low power consumption, low cost, high recovery rate and environment protection and able to implement full cycle regeneration process method of waste lead acid battery.
The above-mentioned purpose of the invention is implemented with the following technical scheme, which is able to implement a full cycle regeneration process method of waste lead acid batteries and includes the following steps:

    
    
        (1) Smashing and separating waste lead acid battery: smashing and separating the waste lead acid battery to obtain grid lead, lead mud and waste electrolyte separately;
        (2a) Smelting: smelting, refining and casting the grid lead separated from Step (1) after being washed, to obtain alloy lead ingot;
        (2b) Filter pressing: lead mud obtained from Step (1) is filter pressed, to separate solid-liquid, among which the main element of the separated liquid is waste electrolyte and the separated solid is diachylon;
        (3a) Purification: purification treatment is made for the waste electrolyte separated from Step (2b) and waste electrolyte obtained from Step (1):
        (3b) Drying: the diachylon separated from Step (2b) is dried;
        (4) Diachylon desulphurization and deoxidation: thermal decomposition is made to the diachylon after being dried in Step (3b) in an airtight desulphurization reactor for desulphurization and deoxidation. Lead sulfate and lead dioxide in the diachylon are decomposed separately into lead monoxide (PbO), and produce sulfur trioxide (SO3) gas;
        (5a) Absorbing: SO3 gas separated from Step (4) is absorbed with sulfuric acid to obtain concentrated sulfuric acid;
        (5b) Mixing paste: powder lead monoxide obtained in Step (4) is added with water to mix into a paste state;
        (6) Coating plate: the lead monoxide paste obtained in Step (5b) is coated on an electrolysis cathode plate and the cathode plate is dried;
        (7) Electrolysis reduction: the cathode plate coated with lead monoxide in Step (6) is put into an electrolytic bath filled with electrolyte for electrolysis at a normal temperature. Direct current is powered on the cathode and anode poles of the electrolyte to make the electrolyte have electrochemical reaction under electrolyte function. The lead monoxide is reduced into sponge lead;
        (8) Peeling sponge lead off: peeling off the sponge lead from the cathode plate;
        (9) Washing sponge lead: washing sponge lead obtained in Step (8);
        (10) Smelting sponge lead: smelting, refining and casting the sponge lead after being washed in Step (9) to obtain metal lead.
    
    


The diachylon of the above-mentioned step in the invention is a mixture consisting of lead sulfate (PbSO4), lead dioxide (PbO2) and lead monoxide (PbO). The main element of the mentioned waste electrolyte is diluted sulfuric acid. The purification treatment of the mentioned waste electrolyte in Step (3a) may adopt purification treatment system of sulfuric acid.
The following improvement may be made to the invention: SO3 gas obtained in Step (4) is sent into the purification treatment of waste electrolyte of Step (3a). The sulfuric acid after being filtrated in the system is used to absorb SO3 gas. so as to obtain concentrated sulfuric acid. After it is electrolyzed and filtrated for purification again, it can be used as an electrolyte material to manufacture new battery, as a result to implement reuse of the regenerated material from waste lead acid battery.
Smelting, refining and casting mode of the grid lead obtained in the above-mentioned Step (1) and sponge lead obtained in Step (7) adopts a separated smelting mode, i.e. both of smelting, refining and casting are performed separately. As the obtained grid lead carries acid and metal oxide powder, and the sponge lead is alkaline after solid electrolysis process, clean water is used to wash the remaining material on the grid lead and sponge lead. And smelting, refining and casting are performed separately, so as to obtain alloy lead ingot and metal lead ingot separately. This way is favorable to improve use of the other heavy metals originally existing in the grid lead, so as to save precious metal put into production of alloy lead ingot and improve the value in use for the recovered grid lead. The alloy lead ingot obtained in Step (2a) may be used as a raw material to manufacture lead acid battery in the production of new lead acid battery. The metal lead ingot obtained in Step (10) may be used as a raw material of diachylon to manufacture lead acid battery in the production of new lead acid battery, as a result to implement regeneration and cycle use of waste lead acid battery.
The above-mentioned Step (1) of the invention is based on the difference of the fractionized density and particle size subdivided into every group of waste lead acid battery. In water medium, a physical method, like a smashing and gravity separating method, is used to separate it, so as to obtain grid lead, waste electrolyte, diachylon and plastic separately. During the whole production process, it is performed automatically in a wet and fully airtight way. There is no pollution created during the production process. All water is reused in cycle and in a airtight way.
Pumping is used to make gas in the system operate under a negative pressure. And then filtration is performed and spray gas is discharged.
The following improvement may also be made to the invention: the grid lead obtained in the above-mentioned Step (2a) after smelting, separating and casting can be used in manufacture of pole plate of lead acid battery.
The plastic obtained in Step (1) of the invention mainly includes polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC). Polypropylene can be reused in production of battery enclosure. Polyethylene and polyvinyl chloride can be reused in the plastic products, which do not need high quality.
In the invention, smelting in above-mentioned Step (1) means that the grid lead is put into a melting pod for smelting. Refining means that the molten lead is flew into a refining pod for refined to remove impurity in the molten lead. Casting means that the refined molten lead is poured into a mold to cast an alloy lead ingot. The melting, separating and casting the sponge lead performed in Step (10) is the same as smelting grid lead.
The above-mentioned Step (2a) and (2b), or Steps (3a) and (3b), or Steps (5a) and (5b) in the invention may separately express two steps, which may be performed synchronously.
In the desulphurization and deoxidation reaction performed for diachylon in the above-mentioned Step (4) of the invention, desulphurization means that the lead sulfated is disassociated for desulphurization. Deoxidization means that the lead dioxide is disassociated for deoxidization. The reduction reaction equation of thermal decomposition for the diachylon in a desulphurization reactor is shown as follows:

PbSO4→PbO+SO3  [a]

PbO2→PbO+0.5O2  [b]

The reaction temperature of the materials mentioned in [a] and [b] may be in the range of 705 ̃830° C. (keeping the material under a non-melted state). Better reaction temperature is in the range of 800 ̃820° C. The disassociation time of the diachylon in a desulphurization reactor is 1 ̃2 hours. It is not necessary to add in any reductive material like NaOH, Fe scrap, etc. during the whole desulphurization and deoxidization process of the diachylon. The concentration of obtained SO3 gas is high. It can form concentrated sulfuric acid in reaction with sulfuric acid. The sulfuric acid obtained in Step (3b) after being filtrated is used to absorb the mentioned SO3 gas. The concentrated sulfuric acid obtained may be reused in production of new lead acid battery and electrolyte after it is purified in an electrolysis way and filtrated, so as to implement regeneration and reuse of sulfuric acid. The desulphurization rate of the lead sulfate may be larger than 98% after disassociation desulphurization. The deoxidation rate is larger than 97% after the lead dioxide has disassociation deoxidation. The particle size of the obtained lead monoxide is in the range of 16 ̃50 MU after thermal decomposition and reduction reaction.
In above-mentioned Step (5) of the invention, the weight proportion of water added in and lead monoxide is in the range of 13:100 ̃18:100.
The invention may be improved further: the electrolysis reduction process in the above-mentioned Step (7) adopts solid phase electrolysis reduction process in a wet way. The electrolyte adopts sodium hydroxide (NaOH) solution. The anode and cathode coated with lead oxide paste are put into an electrolytic bath, i.e. with a certain space. The mentioned anode and cathode implement chemical reaction under the function of direct current and sodium hydroxide electrolyte to reduce lead oxide into sponge lead. Where the mass percentage concentration of the sodium hydroxide electrolyte is in the range of 80%-15%. The electrolysis time is 18 ̃22 hours. Voltage is 1.5-2.5 v, and current is 450-600 A/m2. The chemical reaction equation in the electrolytic bath is shown as follows:

Cathode PbO+H2O+2e=Pb+2OH−  [c]

Anode 2OH−2e=H2O+0.5O2  [d]

In the solid phase reduction electrolysis process in a wet way, an electrolyte cycle filter system can be adopted. The electrolyte in the electrolytic bath is formed as a cycle loop. In the loop, a filter channel, and an electrolyte temperature and concentration control unit are set up to collect sponge lead in the electrolyte and keep the electrolyte temperature and concentration stable, which will be favorable for improving electrolysis efficiency. As the lead sulfate desulphurization efficiency can reach more than 98% in Step (4), the remaining lead sulfate is electrolyzed in the electrolyte of Step (7). Its reaction equation is: PbSO4+2e=Pb+SO42−, and then Na2SO4 is produced. Therefore, minim PbSO4 will neither cause any affection on electrolysis nor create the pollution problem due to SO2 gas separated out.
As grid lead and sponge lead are fine particles, it is not so easy to be melted like large massive lead ingot. In order to increase the direct recovery rate of metal lead, this invention adopts a screw pressure feeder to press grid lead or sponge lead directly into a melting pot. They are melted under an airtight condition as a separately melting mode. Melting process of the grid lead or sponge lead is a physical melting process to be heated indirectly in a melting pot. High-temperature flaming gas transfers heat to the melting pot indirectly. Flaming waste gas is waste gas as fuel itself, which can be used as used heat. Oxygen-enriched combustion is adopted to be more favorable for decreasing waste gas quantity.
Refining is to remove impurity in the molten lead. The mentioned impurity in this invention means minim non-reduction oxide, like lead oxide. And in the refining process, it is required to ad in metals, such as calcium, stibonium, according to the element of battery grid plate to remove the impurity in the molten lead. Some oxidant is used usually to oxidize un-necessary metal to form dross for removal.
After the above-mentioned refuting Step (10), the direct recovery rate of metal lead can reach more than 96%; Produced dross is 3 ̃4%. The main element of dross is lead oxide. It will be reused after being ground. The total lead recovery rate is more than 99%.
This invention may be improved as follows: the process includes a waste water treatment step: the waste water produced in the above-mentioned Steps (1) ̃(10) is collected into a waste water treatment system. After it is purified, it can be reused in cycle to implement zero discharge of production water. It both complies with the requirement of environment protection and save water resource:
In order to be easy to compare, the invention process and solid phase electrolysis reduction process and electrolysis deposition process in a wet way are compared, shown in the following table:







TABLE 3







Comparison table of process efficiency of this invention and other electrolysis technology.













Full cycle regeneration


Process
Solid phase electrolysis
Electrolysis deposition process
process of waste lead


technology
reduction process
in a wet way
acid battery of this invention





Process
There are no
Material separating. Na2CO3 is used
Material is separated as a


comparison
desulphurization and lead
for desulphurization conversion.
pre-treatment. Airtight



dioxide disassociation
Heat decomposition is used for
disassociation



processes after raw
PbCO3 and PbO2 disassociation
desulphurization,



material is sorted. Multi
into PbO. Silicofluoric acid is used
deoxidation, solid phase



lead compounds are
to leach-out PbO into lead ion -
electrolysis reduction are



directly under solid phase
deposition electrolysis reduction.
adopted. No need to add



electrolysis.

any reduction materials





such as NaOH, Na2CO3,





Fe scrap, etc.


Desulphurization
During the electrolysis
Na2CO3 is adopted for
Heat decomposition


method
process, NaOH is used to
pre-treatment. After
mode is used for



substitute sulfur in
desulphurization, decomposition is
desulphurization in



PbSO4.
performed.
PbSO4 and PbO2





decomposition.


Desulphurization
NaOH is used in
The cost to Na2CO3 for
Disassociation


scheme
electrolysis process for
substitution and desulfurization is
technology is used for


comparison
substitution and
high. Treatment and recovery of
desulphurization. No



desulfurization, and to
Na2SO4 is easier compared to solid
other material is used for



form Na2SO4. It is
phase electrolysis (separation of
substitution, so as so



difficult to treat and
solid and liquid), but cost is high.
save raw material. Cost



recover (cooling
Lead consumption per T is more
is low. Only little heat



electrolyte). Cost is very
than 200 Kg Na2CO3
energy is consumed,



high. Lead consumption

40 Kg coal/T lead.



per T is more than



150 Kg NaOH.


Deoxidation
No disassociation PbO2
After substitution, disassociation
Disassociation takes


decomposition

PbO2, is performed. One more step.
place at the same time of





PbO2 disassociation.


PbO2 affection
PbO2 occupies more than
Although PbO2 disassociation is
No PbO2 is produced


on electrolysis
40% of raw material.
done, the anode is easy to
during electrolysis



40% more power
re-produce PbO2 in the electrolysis
process. The remaining



consumption.
process, which causes high power
PbO2 can be reduced




consumption and unstable
during electrolysis




production factor. Remaining PbO2
process. Direct recovery




is not dissolved in silicofluoric
rate is high.




acid. Direct recovery rate is low.


PbSO4 affection
Electrolysis process
PbSO4 is difficult to be dissolved in
Remaining minim


on electrolysis
continuously produces
silicofluoric acid. Desulphurization
PbSO4 is reduced into



Na2SO4 to cause element
conversion is not thorough, which
metal lead during



change of the electrolyte
affects direct metal recover.
electrolysis process. The



and unstable electrolysis

direct recovery rate is



condition.

high. It will produce





minim Na2SO4, no large





affection on electrolyte





element.


Electrolysis cycle
24 hours. High power
72~96 hours. High power
18 hours. Low power



consumption 1000 Kwh/T
consumption 1400 Kwh/T
consumption, 500



sponge lead
electrolysis lead.
Kwh/T sponge lead


Pole plate to fall
Sponge lead is formed.
Lead is sheet, easy to fall off.
Sponge lead is formed.


lead off. Coating
Na2SO4 is available,

No Na2SO4, easy to fall


plate mode
difficult to fall off.

off.


Direct recovery
>85%
>88%, non-thorough conversion
>88% (solving


(diachylon to

part of PbSO4 and PbO2, unable to
diachylon to fall off.)


sponge lead)

be electrolyzed and leached out.


Product quality
Lead purity >99.95%
Lead purity >99.99%
Lead purity >99.95%


By-product
Na2SO4, low market
Na2SO4, low market demand. Low
H2SO4, high market



demand. Low price.
price. Unable to use itself.
demand. High price. It is



Unable to use itself.

a production material of





battery, able to reuse in





cycle.


Electrolyte
NaOH solution
Smell of silicofluoric acid is large.
NaOH solution


Production cost
High, electrolysis is
Tiptop
Low, able to enlarge



uneven. Only small-scale

pole piece, to improve



production.

efficiency, able to make





a large-scale production.









The core of this invention is “raw material pre-treatment of waste lead acid battery—disassociation desulphurization and deoxidation of diachylon under an airtight condition—solid phase electrolysis reduction in a wet way—manufacture of new lead acid battery” process. Comparing with the current technology, as for the environment protection, low energy consumption and low cost to implement a large-scale industrial production of full cycle regeneration in a wet way, it has the following significant effect:

    
    
        (1) The regeneration process of waste lead acid of this invention makes it possible to implement full cycle regeneration of waste lead acid batteries so as to completely reuse them in manufacturing new batteries. This invention provides a process starting from the step of smashing and separating to regeneration of grid lead and lead mud. The plastic, alloy lead, metal lead and sulfuric acid, which are obtained separately, can be used as materials in manufacturing new batteries. The entire process to implement full cycle regeneration of waste lead acid batteries only need consume sodium hydroxide electrolyte. All the materials to manufacture new batteries can be obtained from the regeneration process of waste batteries. In this way, it not only saves cost and resources, but also solves the difficult problems concerning environment protection caused by waste batteries.
        (2) The smashing and separating step of the regeneration process of the present invention can effectively separate metal and plastic, grid lead and metal oxide diachylon, making them easy for further regeneration treatment. It not only solves the problem of diachylon conversion and desulphurization for creating a condition to increase the recovery value of metal lead, but also improves other metal reuse value in grid alloy lead.
        (3) The diachylon disassociation desulphurization and deoxidation step of the regeneration process of the present invention is conducted in an airtight reactor and does not need adding substitution chemical material. It consumes lower heat energy and uses a heating mode to make disassociation for the sulfide and oxide in the raw material. The production cost is about 10% of what is for the substitution method. The method adopts an airtight disassociation mode, and is able to increase sulfur trioxide concentration so that it can be decomposed most effectively. The sulfur trioxide concentration obtained is high, and thus can be used a raw material to manufacture sulfuric acid. Regeneration rate of material is high and production cost of sulfuric acid is low. In addition, the value of sulfuric acid is several times higher than that of sodium sulfate. Therefore this process is the most advanced method for saving energy, decreasing discharge and regeneration.
        (4) This invention adopts a disassociation desulphurization and deoxidation technology for desulphurization of the lead sulfate in diachylon and for deoxidation of the lead dioxide in diachylon under an airtight condition. Both can be converted to lead monoxide, whose electrolysis energy consumption is the lowest, thereby decreasing the cost of electrolysis energy consumption in the next solid phase electrolysis process for lead sulfate and lead dioxide, with about a 40% decrease in power consumption. It can also solve the problems of the loss of electrolyte sodium hydroxide and unstable concentration.
        (5) This invention overcomes the shortcoming of direct electrolysis of diachylon in the original solid phase electrolysis process. Different kinds of lead chemical compounds in diachylon are changed into a single type lead oxide for electrolysis. In this way, it can effectively overcome several unstable factors in the electrolysis process of solid phase electrolysis, thereby achieving stable electrolysis condition, low power consumption, no sodium sulfate produced in the electrolysis process, and playing a very important role in decreasing production cost, using electrolysis with large-area pole plates, and implementing modernization and large-scale production.
        (6) The solid phase electrolysis reduction process of the present invention utilizes an electrolyte cycle filter system to collect the sponge lead in electrolyte, so as to further increase recovery rate of sponge lead and keep a stable condition for electrolyte temperature and concentration, which help to enhance the electrolysis efficiency.
        (7) The coating plate step of the present invention can be performed under a fully wet condition, without involving any any chemical reaction process and dust producing process. The entire process of mixing paste, coating plate and drying can be performed under an airtight condition, which helps improvement of environment protection in the production process.
        (8) The smashing, the refining and casting of grid lead and sponge lead in this invention adopts a separately melting and smelting mode. The separately melting mode adopted by both helps create a condition for increasing recovery value of metal lead. It not only solves the conversion problem of diachylon desulphurization, but also increases the utilizaiton rate of the other heavy metals in the grid lead. As a result, there is a reduction in the amount (and the cost) of the expensive metal element (for example, Se) that needs to be added into lead ingot again in lead alloy production.
        (9) The metal recovery rate of this invention is high, which can reach more than 99%. The recovery rate of residue acid is 100%. Plastic recovery rate can reach 99%. Power consumption for every ton of sponge lead produced is about 500 Kw, reaching electrolysis efficiency ≧96%, recovery rate of metal lead ≧99%, and purity of recovered lead reaches 99.95%.
        (10) The entire process of the present invention is under an airtight condition in a fully wet way. The sulfur trioxide gas produced with the process is completely absorbed to be used in manufacturing sulfuric acid, as a raw material of electrolyte for making new battery. There is not any waste gas discharged during the production process. And the process does not discharge any waste residue. Waste water produced in the production process is reused in cycle totally under an airtight condition, resulting in zero discharge of waste water. The process of this invention can fully meet with the requirement of environment protection: discharges of none waste water, none waste gas and none waste residue, or the “three-none” standard.
    
    





BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart to implement the full cycle regeneration process of waste lead acid battery, as one of the Invention Implementation Examples of the present invention;
FIG. 2 is a flow chart of electrolyte cycle filter system used in the solid phase electrolysis reduction process in a wet manner, which is one of Invention Implementation Examples of the present invention.



IMPLEMENTATION EXAMPLE 1
As shown in FIGS. 1 and 2, it is a full cycle regeneration process of waste lead acid batteryies, which represents one of Invention Implementation Examples. It includes the following steps:

    
    
        (1) Smashing and separating waste lead acid battery: smashing and separating waste lead acid battery to obtain alloy lead, lead mud, plastic and waste electrolyte, i.e., the diluted sulfuric acid, separately;
        (2a) Smelting: grid lead separated from Step (1) is smelted, refined and cast after being washed. The obtained alloy lead ingot will be used in the manufacture of the battery pole plate. Smelting in Step (1) means that the grid lead is put into a melting pod for melting. Refining means that the molten lead is refuted in a refining pod to remove impurities in the molten lead. Casting means that the refined molten lead is poured into a mold to cast an alloy lead ingot.
         The separating process of waste lead acid battery is a step in which the waste battery is smashed in a crusher. The material then passes a vibration screen. Less than 1 mm diachylon is separated out by the vibration screen. This part of diachylon is formed into lead mud with electrolysis acid liquor. Grid lead and plastic larger than 1 mm enter a gravity separation system of grid lead and plastic on the upper surface of the vibration screen. According to the difference of specific gravity, plastic and grid lead are separated out. The last plastic part is further separated in a plastic separating system according to the difference of plastic specific gravity to separate out polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC). The known technology is adopted to treat the separated plastic, for reusing polypropylene in production of plastic battery enclosures and reusing polyethylene and polyvinyl chloride in the other plastic products, for which the materials do not need be of high quality.
        (2b) Filter pressing: the lead mud obtained from Step (1) is filter pressed to separate the solid from the liquid, among which the main element of the separated liquid is waste electrolyte, i.e., diluted sulfuric acid, and the separated solid is diachylon. The mentioned diachylon is a mixture consisting of lead sulfate (PbSO4), lead dioxide (PbO2) and lead monoxide (PbO);
        (3a) Purification: the purification treatment is conducted on the waste electrolyte separated from Step (2b) and waste electrolyte obtained from Step (1); Step (2a) smelting and (2b) filter pressing can be performed at the same time;
        (3b) Drying: the diachylon separated from Step (2b) is dried;
        (4) Desulphurization and deoxidation for diachylon: disassociation desulphurization and deoxidation process of diachylon is performed under an airtight condition. The diachylon after being dried in Step (3) makes desulphurization and deoxidation in an airtight desulphurization reactor. All the lead sulfate in diachylon is decomposed into lead monoxide (PbO), whose electrolysis energy is the lowest, and used to produce sulfur trioxide (SO3). All the lead dioxide in diachylon is converted into lead monoxide (PbO), whose electrolysis energy is the lowest. The particle size of the lead monoxide obtained in the step is about 20 MU (or mesh);
         The diachylon reaction equation of heat reduction in the desulphurization reactor is shown as follows:

PbSO4→PbO+SO3  [a]

PbO2→PbO+0.5O2  [b]

         The reaction temperature of the material in the above-mentioned [a] and [b] is 800° C. The disassociation time of the diachylon in the desulphurization reactor is 2 hours;
        (5a) Absorbing: SO3 gas separated out in Step (4) is sent into a purification system of sulfuric acid in Step (3b). It reacts with the filtrated sulfuric acid to obtain concentrated sulfuric acid. The mentioned concentrated sulfuric acid is electrolyzed, purified and filtrated again to be used as the electrolyte material for battery manufacturing;
        (5b) Mixing paste: the lead monoxide powder obtained in Step (4) is mixed with water to form a paste. The weight ratio of the added water over the lead monoxide is 13:100;
        (6) Coating plate: the lead monoxide paste obtained in Step (5) is coated on electrolysis cathode plate 2, which is then dryed;
        (7) Electrolysis reduction: a “wet” solid phase reduction process is adopted. The electrolyte uses a sodium hydroxide (NaOH) solution. Cathode plate 2 coated with lead monoxide in Step (6) is put into electrolytic bath 1 filled with the sodium hydroxide (NaOH) solution for electrolysis at room temperature. Direct current is powered between the cathode and anode poles in the electrolyte so that the electrolyte undergoes electrochemical reaction under the mentioned conditions. The lead monoxide is reduced into sponge lead; Mass percentage concentration of the sodium hydroxide electrolyte is 8%. Electrolysis time is 18 hours. Anode and cathode coated with lead monoxide paste are put into electrolytic bath 1. Voltage is 2 v and current is 500 A/m2. The chemical reaction equation in electrolytic bath 1 is shown as follows:

Cathode PbO+H2O+2e=Pb+2OH−  [c]

Anode 2OH−2e=H2O+0.5O2  [d]

         In the “wet” solid phase electrolysis reduction process, an electrolyte cycle filter system is adopted, in which filter channel 3, electrolyte regulating tank 6 and electrolyte concentration control unit are added. The mentioned filter channel 3 and electrolyte regulating tank 6 are joined with electrolytic bath 1 to form an electrolyte cycle loop with pipe 5. The function of filter channel 3 is to collect sponge lead in the electrolyte by filter unit 3a. The electrolyte concentration control unit includes pump 4, electrolyte temperature/concentration inductor and control circuit board. Functionally, the electrolyte temperature/concentration inductor monitors the electrolyte concentration, and sends an operation signal to the control circuit according to the inductor's state. Control pump 4 runs to keep a stable electrolyte temperature and concentration;
        (8) Peeling sponge lead off: the sponge lead is peeled off from cathode plate 2;
        (9) Washing of sponge lead: sponge lead obtained in Step (8) is washed;
        (10) Refining: smelting, refining and casting the sponge lead after being washed in Step (9) to obtain metal lead;
         The smelting, refining and casting mode of sponge lead is the same process as that of smelting grid lead. The only difference is to adopt a separately melting mode, i.e., smelting, refining and casting are performed separately for sponge lead and for grid lead. Such separating mode is better for further treatment of grid lead, resulting in better use and treatment of metal lead improvement in its recovery value. The grid lead, directly smashed and separated from waste lead acid battery and processed into alloy lead in the melting recovery process, can be used to manufacture battery pole plates, with great cost savings.
        (11) Regeneration of lead acid battery: the plastics obtained in Step (1) mainly include polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC). Polypropylene can be reused in production of battery enclosures. Polyethylene and polyvinyl chloride can be reused in those plastic products which do not require high quality of materials. The sulfuric acid obtained in Steps (1) and (4) can be used to absorb SO3 gas produced in Step (4) to produce concentrated sulfuric acid. After it is electrolyzed, purified and filtrated, it will become a raw material to produce electrolyte in new lead acid batteries. The alloy lead obtained in Step (2a) and the metal lead obtained in Step (10) will become a raw materials to manufacture the pole plate and diachylon, respectively, in new batteries. As such, all the parts from waste lead acid batteries can be regenerated and reused in the manufacture of new lead acid batteries, i.e., a full cycle regeneration of waste the lead acid battery is achieved.
         In the present invention, the above-mentioned Steps (2a) and (2b) can be performed simultaneously. The same applies to Steps (3a) and (3b), and to Steps (5a) and (5b).
         This invention may also include a waste water treatment system: the waste water produced in the above-mentioned Steps (1) ̃(10) is collected into a waste water treatment system. After being purified, it is to be recycled and reused to realize zero discharge of waste water.
         The entire production process, including mixing paste, coating plate and drying, is performed under an airtight condition in a fully wet manner.
    
    


IMPLEMENTATION EXAMPLE 2
The differences from Implementation Examples 1 are: in Step (4), in the desulphurization rector, the reaction temperature of the material is 805° C. C. The disassociation time of the diachylon in the desulphurization reactor is 1.8 hours. In Step (5b), the weight proportion of water in lead monoxide paste and lead monoxide is 15:100. In Step (7), the mass percentage concentration of sodium hydroxide electrolyte is 10%. Electrolysis time is 19 hours.
IMPLEMENTATION EXAMPLE 3
The differences from Implementation Examples 1 are: in Step (4), in the desulphurization rector, the reaction temperature of the material is 810° C. The disassociation time of the diachylon in the desulphurization reactor is 1.5 hours. In Step (5b), the weight proportion of water in lead monoxide paste and lead monoxide is 15:100. In Step (7), the mass percentage concentration of sodium hydroxide electrolyte is 10%. Electrolysis time is 20 hours.
IMPLEMENTATION EXAMPLE 4
The differences from Implementation Examples 1 are: In Step (4), in the desulphurization rector, the reaction temperature of the material is 815° C. The disassociation time of the diachylon in the desulphurization reactor is 1.2 hours. In Step (5b), the weight proportion of water in lead monoxide paste and lead monoxide is 16:100. In Step (7), the mass percentage concentration of sodium hydroxide electrolyte is 12%. Electrolysis time is 21 hours.
IMPLEMENTATION EXAMPLE 5
The differences from Implementation Examples 1 are: in Step (4), in the desulphurization rector, the reaction temperature of the material is 820° C. The disassociation time of the diachylon in the desulphurization reactor is 1 hour. In Step (5b), the weight proportion of water in lead monoxide paste and lead monoxide is 18:100. In Step (7), the mass percentage concentration of sodium hydroxide electrolyte is 15%. Electrolysis time is 22 hours.

## Claims

1. A method for a full cycle regeneration process of waste lead acid batteries, comprising the following steps:
(1) smashing and separating waste lead acid batteries to obtain grid lead, lead mud and waste electrolyte separately;
(2a) smelting, refining and casting the grid lead separated from Step (1) after being washed, to obtain alloy lead ingot;
(2b) filter pressing the lead mud obtained from Step (1) to separate solid and liquid, the main element of the separated liquid being waste electrolyte and the separated solid being diachylon;
(3a) purifying the waste electrolyte separated from Step (2b) and waste electrolyte obtained from Step (1);
(3b) drying the diachylon separated from Step (2b);
(4) thermal decomposing the diachylon after being dried in step (3b) in an airtight desulphurization reactor for desulphurization and deoxidation, with the lead sulfate and lead dioxide in the diachylon being decomposed separately into lead monoxide (PbO), and producing sulfur trioxide (SO3) gas;
(5a) absorbing the SO3 gas separated from Step (4) with sulfuric acid to obtain concentrated sulfuric acid;
(5b) mixing the powder-type lead monoxide obtained in Step (4) with water to obtain a lead monoxide paste;
(6) coating the lead monoxide paste obtained in Step (5b) on an electrolysis cathode plate and drying the cathode plate;
(7) immersing the cathode plate coated with lead monoxide in Step (6) into an electrolytic bath filled with electrolyte and performing electrolysis at room temperature with direct current supplied to cathode and anode poles to reduce the lead monoxide is reduced into sponge lead;
(8) peeling off the sponge lead from the cathode plate;
(9) washing the sponge lead obtained in Step (8);
(10) smelting, refining and casting the sponge lead after being washed in Step (9) to obtain metal lead.

2. The method according to claim 1, wherein in Step (4), desulphurization and deoxidation reaction for diachylon is conducted in a desulphurization reactor, in which desulphurization is disassociation desulphurization of lead sulfated and deoxidation is disassociation deoxidation of lead dioxide, and heat reduction reaction equation of diachylon in said reactor is shown as follows and are conducted at a temperature within the range from 705 to 830° C.:


PbSO4→PbO+SO3  (a)



PbO2→PbO+0.5O2  (b)

3. The method according to claim 2, wherein the reaction temperature reactions (a) and (b) is in the range of 800 ̃820° C., which are performed for 1 ̃2 hours.

4. The method according to claim 3, wherein the smelting, refining and casting mode of the grid lead obtained in Step (1) and the sponge lead obtained in Step (7) adopt separate melting mode, and Step (2a) and Step (10) are performed separately.

5. The method according to claim 4, wherein the alloy lead ingot obtained in Step (2a) becomes a suitable raw material to manufacture the pole plate for new lead acid batteries and the lead ingot obtained in Step (10) becomes a suitable raw material to manufacture diachylon for a new lead acid battery.

6. The method according to claim 1, wherein the SO3 gas obtained in Step (4) is sent to said waste electrolyte in Step (3a) which absorbs the SO3 gas to produce concentrated sulfuric acid.

7. The method according to claim 6, wherein after the concentrated sulfuric acid is electrolyzed, purified and filtrated, it becomes a suitable raw material to manufacture electrolyte for a new lead acid battery.

8. The method according to claim 1, wherein the weight proportion of the water and lead monoxide is in the range of 13:100 ̃18:100 as in Step (5b).

9. The method according to claim 8, wherein the electrolysis reduction process in Step (7) is a wet type of solid phase electrolysis reduction process; the electrolyte is sodium hydroxide solution; the anode and cathode coated with lead oxide paste are immersed into an electrolytic bath; the anode and cathode perform the chemical reaction as the function of direct current and sodium hydroxide electrolyte to reduce lead oxide into sponge lead; the sodium hydroxide electrolyte is in the range of 8% ̃15% by weight; and the chemical reactions in the electrolytic bath, performed for 18-22 hours, are as follows:


Cathode PbO+H2O+2e=Pb+2OH−  (c)



Anode 2OH−2e=H2O+0.5O2  (d).

10. The method according to claim 9, further comprising a waste water treatment step to purify waste water collected from Steps (1) ̃(10) so that it can be reused in cycle to realize zero discharge of waste water.