Systems and methods for purifying and recycling lead from spent lead-acid batteries

Patent metadata

Field	Value
Publication number	US-2017338531-A1
Application number	US-201715674028-A
Country	US
Kind code	A1
Filing date	Aug 10, 2017
Priority date	Jun 20, 2014
Publication date	Nov 23, 2017
Grant date	—

Abstract

The present disclosure relates to systems and methods by which lead from spent lead-acid batteries may be extracted, purified, and used in the production of new lead-acid batteries. The system includes a first phase separation device configured to: receive the first mixture from the basic lead stream digestion device, isolate a liquid component from one or more insoluble components of the first mixture, and output the liquid component. The system also includes a lead salt precipitation device configured to: receive and mix the liquid component and a carboxylate source to form a second mixture including a lead salt precipitate, and output the second mixture. The system further includes a second phase separation device configured to: receive the second mixture from the lead salt precipitation device, isolate the liquid component from the lead salt precipitate of the second mixture, and output the lead salt precipitate.

First claim

1 . A system, comprising:
a basic lead stream digestion device configured to: receive and mix a hydroxide and a lead-bearing material to form a first mixture, and output the first mixture; a first phase separation device configured to: receive the first mixture from the basic lead stream digestion device, isolate a liquid component from one or more insoluble components of the first mixture, and output the liquid component; a lead salt precipitation device configured to: receive and mix the liquid component and a carboxylate source to form a second mixture comprising a lead salt precipitate, and output the second mixture; and a second phase separation device configured to: receive the second mixture from the lead salt precipitation device, isolate the liquid component from the lead salt precipitate of the second mixture, and output the lead salt precipitate.

2 . The system of claim 1 , comprising a lead-acid battery processing device configured to: receive at least one lead-acid battery, grind the at least one lead-acid battery into the lead-bearing material, and to output the lead-bearing material.

3 . The system of claim 1 , comprising a impurity gas removal device configured to: receive the liquid component from the first phase separation device, mix the liquid component with a compound that evolves one or more impurity gases from one or more impurities of the liquid component, and output the liquid component to the lead salt precipitation device without the one or more impurities.

4 . The system of claim 1 , wherein the pH of the first mixture in the basic lead stream digestion device is greater than 7.

5 . The system of claim 1 , wherein the pH of the first mixture in the basic lead stream digestion device is between 8 and 14.

6 . The system of claim 1 , wherein the first phase separation device comprises a filter press, a clarifier, or a cyclone separator.

7 . The system of claim 1 , wherein the second phase separation device comprises a belt dryer or a spray dryer configured to: remove the lead salt precipitate from the third mixture, and heat and dry the lead salt precipitate.

8 . The system of claim 7 , wherein the belt dryer is further configured to at least partially oxidize the lead salt precipitate into leady oxide while heating and drying the lead salt precipitate.

9 . The system of claim 1 , wherein the pH of the second mixture in the lead salt precipitation device is 7 or below.

10 . The system of claim 1 , wherein the pH of the second mixture in the lead salt precipitation device is between approximately 2 and approximately 6.

11 . The system of claim 1 , comprising a lead salt precipitate treatment device configured to: receive the lead salt precipitate from the second phase separation device, treat the lead salt precipitate to form leady oxide, and output the leady oxide.

12 . The system of claim 11 , wherein the leady oxide comprises between approximately 0% and approximately 35% free lead.

13 . The system of claim 11 , wherein the leady oxide comprises leady oxide particles having a D 50 between approximately 0.2 μm and approximately 20 μm.

14 . The system of claim 11 , wherein the leady oxide has a BET surface area greater than approximately 2.5 square meters per gram (m 2 /g).

15 . The system of claim 11 , wherein the leady oxide has an acid absorption greater than approximately 250 milligrams H 2 SO 4 per gram.

16 . The system of claim 11 , wherein the leady oxide comprises less than approximately 20% beta phase lead oxide.

17 . The system of claim 11 , wherein the lead salt precipitate treatment device comprises a spray calciner configured to: receive the lead salt precipitate from the second phase separation device, atomize the lead salt precipitate, mix the atomized lead salt precipitate with a gaseous stream to oxidize the lead salt precipitate into leady oxide particles, and output the leady oxide particles.

18 . The system of claim 11 , wherein the lead salt precipitate treatment device comprises a stirred pot reactor configured to: receive the lead salt precipitate from the second phase separation device, mix the lead salt precipitate with a gaseous stream using an agitator to oxidize the lead salt precipitate into leady oxide, and output the leady oxide.

19 . The system of claim 11 , wherein the lead salt precipitate treatment device comprises a rotary kiln calciner configured to: receive the lead salt precipitate from the second phase separation device, introduce the lead salt precipitate into the top of a rotating tube furnace of the rotary kiln calciner, mix the lead salt precipitate with a gaseous stream to oxidize the lead salt precipitate into leady oxide within the rotating tube furnace, and output the leady oxide at a bottom of the rotating tube furnace.

Assignees

• Johnson Controls Tech Co

Inventors

• Spence Matthew A
• Curran Patrick M

Classifications

• H01M10/54 Primary

  Reclaiming serviceable parts of waste accumulators · CPC title

• H01M6/52

  Reclaiming serviceable parts of waste cells or batteries {, e.g. recycling} · CPC title

• C22B3/04

  by leaching (C22B3/18 takes precedence) · CPC title

• B01J6/001

  Calcining · CPC title

• C22B7/007

  by acid leaching · CPC title