What Makes a Complete Lead-Acid Battery Recycling Plant?
A complete lead-acid battery recycling plant is a turnkey solution that converts end-of-life batteries into lead ingots, clean plastic granules, and neutralised residues while meeting strict environmental standards. We provide the full process chain: battery breaking and separation machine, rotary smelting furnace, lead refining plant, ingot casting, plastic crushing and washing, acid neutralisation, wastewater treatment, and comprehensive fume and dust collection and treatment.
Core Lead-Acid Battery Recycling Equipment & Process Modules
1. Battery Breaking and Separation Machine
The battery breaking and separation machine is the heart of any lead-acid battery recycling line. It safely crushes whole batteries and separates lead paste, lead grids, plastics, and acid. The separation efficiency reaches over 98% for lead and 99% for plastics.
2. Rotary Smelting Furnace
The rotary smelting furnace smelts lead paste, grids, and other lead-bearing residues. Our furnace uses natural gas, diesel, or heavy oil burners with oxygen enrichment to reduce fuel consumption. The slag is tapped separately, and lead is tapped into ingot moulds.
3. Lead Refining Plant and Ingot Casting
Crude lead from smelting requires refining to meet market specifications (e.g., 99.97% pure lead). Our lead refining plant uses pyrometallurgical processes: desulphurisation, de-coppering, softening, and final refining. The refined lead is then cast into ingots using automatic casting machines.
4. Plastic Crushing and Washing
Battery cases (polypropylene) are crushed and washed to remove acid and lead dust. Our plastic crushing and washing line includes a wet granulator, friction washer, float-sink tank, and centrifugal dryer.
5. Acid Neutralisation and Wastewater Treatment
Our acid neutralisation system includes reaction tanks, pH control, and sludge dewatering. The wastewater treatment module uses chemical precipitation, flocculation, and filtration to remove heavy metals (lead, antimony, arsenic).
6. Comprehensive Fume and Dust Collection and Treatment
Comprehensive fume and dust collection and treatment system captures emissions at each source: breaking, smelting, refining, and casting. It includes hoods, ducting, bag filters, HEPA filters, and wet scrubbers. The final emissions meet EU and US EPA standards.
Engineering Services: Installation, Commissioning, Training & Spare Parts
A plant is only as good as its installation and operation. We provide:
- Installation: Our engineers supervise mechanical and electrical installation on-site.
- Commissioning: We test each module, optimise parameters, and run trial production.
- Operator training: Your team learns safe operation, maintenance, and troubleshooting.
- Spare parts for one year: We supply critical wear parts (mill hammers, furnace liners, filter bags, pump seals) to avoid downtime.
Why Choose Our Lead-Acid Battery Recycling Plant?
- Proven technology: Over 30 installations in Asia, Africa, and Europe.
- Environmental compliance: Meets stringent emission and effluent norms.
- High ROI: Lead recovery > 99%, low energy consumption.
- Customisable capacity: 50,000 to 300,000 tons per year.
- After-sales support: 24/7 remote assistance and on-site service.
Get Your Free Lead Recycling Plant Quote
Ready to build a profitable lead-acid battery recycling plant? Contact Guanma Machinery engineers for a process flow, and budget estimate. We tailor the battery breaking and separation machine, rotary smelting furnace, lead refining plant, and auxiliary systems to your battery chemistry and local regulations.
📩 Get Your Free Quote Today
Contact us today to discuss your project, capacity requirements, and target materials. Our team will reply within 24 hours with a customized proposal. You can also reach us directly at [email protected] — we are here to help!
