Lead-Acid Battery Processing System Flow
Guanma Machinery walk you through the full‑flow of a lead‑acid battery processing system that turns hazardous scrap into high‑purity lead bullion, clean polypropylene chips, and safely treated acid.
1. Battery Feed System & Battery Breaker
Automated battery feed system accepts whole scrap batteries directly from pallets. Battery breaker crushes the casings without shredding the internal lead components. The result is a controlled stream of mixed material — paste‑covered grids, separators, and polypropylene fragments.
2. Broken Battery Float/Sink Separation System
Once broken, the material drops into a float/sink separation system. The acid‑soaked pieces, heavy lead‑bearing paste, metallic grids, and lightweight PP plastic naturally segregate in a water‑based medium. A dedicated acid separation in battery processing circuit drains and neutralizes the sulfuric acid. Polypropylene floats and is skimmed off, washed, and extruded into reusable plastic pellets, while the lead‑rich sink fraction is dewatered and sent to the screening stage.
3. Lead Material Screening System & Silica Separator Removal
The sunk material — a mixture of lead paste, small metallic particles, grid fragments, and silica‑based separators — enters a lead material screening system. A multi‑deck vibrating screen combined with a wet scrubbing trommel separates the fine battery paste (lead sulfate and lead oxide) from the larger metallic grids and posts.
4. Silica Separator Removal
Silica separator removal is achieved through float‑off skimming, ensuring the metallic fraction is free of refractory impurities. The clean grid metal goes directly to smelting, while the fine paste slurry proceeds to desulphurization.
5. Soda Ash Battery Paste Sulphuration & Filtration
The battery paste, rich in lead sulfate, is pumped to a sulfuration reactor. In this soda ash battery paste sulphuration and filtration process, the lead sulfate is chemically converted to lead carbonate. The resulting lead carbonate cake is pressed to low moisture and can be fed directly to a short rotary furnace.
6. Ammonia Battery Paste Sulphuration & Filtration
Ammonia battery paste sulphuration and filtration system offers a closed‑loop alternative. Here, ammonium carbonate reacts with the lead sulfate paste to form lead carbonate, while ammonia is recovered, condensed, and reused.
7. Bullion Refining Kettles & Equipment
Metallic grids, posts, and the desulphurized paste are charged into a high‑efficiency rotary furnace and reduced to crude lead bullion. That bullion is then transferred to a series of lead bullion refining kettles and equipment — heated pots where controlled cooling, alloying, and drossing produce 99.985%+ pure lead.
8. Ingot Stacking Equipment
Complementing the kettles are ingot casting conveyors, automated stacking robots, and fume capture hoods, all engineered to maximize output and operator safety.
Why a Complete Lead‑Acid Battery Processing System Pays Back
Your used lead‑acid battery recycling plant benefits from:
- Higher lead recovery (99%+ metallic yield)
- Clean PP plastic separation ready for sale
- Reduced smelting flux consumption and lower slag generation
- Compliance with international emissions and wastewater standards
- Modular design that lets you expand capacity as feed volume grows
Whether you are establishing a new ULAB processing machinery line or upgrading an existing lead recovery system, we can tailor a Lead‑Acid Battery Processing System to your exact capacity, site layout, and product quality goals.
Ready to Turn Scrap Batteries into Pure Lead Bullion?
Contact Guanma Machinery today for a detailed proposal and 3D layout of your future battery recycling plant.
Recommended reading
- Battery Breaking and Separation Unit for Lead Recycling Plant
- Lead Acid Battery Recycling Machine Supplier and Manufacturer
- How to Choose a High-Efficiency Lead Batteries Recycling Line for Your Plant
📩 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!
