Horizontal Cathode Electrolyzer for Lead Recovery

Solution Overview

Problem

Current electrolytic processes for recovering lead from lead acid batteries are inefficient and environmentally harmful, as they require high-temperature smelting, produce undesirable side products, and struggle with scalability and cost-effectiveness, especially in achieving high purity levels.

Innovation Solution

The implementation of a horizontal cathode electrolyzer system that performs solid-state electrolysis on a slurry of impure lead paste with supplemental chemicals, allowing for the separation and melting of near-pure lead without smelting, using a process that includes desulfurization and mechanical separation of dross for additional processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional high-temperature smelting is used to recover lead from lead acid batteries, then lead recovery is achieved, but energy consumption is high and environmental pollution occurs

Engineering Contradiction:

Improvelead recovery processVSAvoidenergy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent changes the fundamental parameter of processing temperature from high-temperature smelting to low-temperature electrolysis. The electrolytic process operates at ambient or mildly elevated temperatures, dramatically reducing energy consumption while achieving effective lead recovery from lead acid battery paste

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal-mechanical smelting system with an electrochemical system. Instead of using high-temperature heat and mechanical stirring, the invention uses electrical current to drive the electrolytic reaction that deposits pure lead at the cathode, eliminating the need for fuel combustion and high-temperature equipment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If traditional high-temperature smelting is used to recover lead from lead acid batteries, then lead recovery is achieved, but environmental pollution is generated

Engineering Contradiction:

Improvelead recovery processVSAvoidenvironmental pollution

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the thermal-mechanical smelting system with an electrochemical system. Instead of using high-temperature heat and mechanical stirring, the invention uses electrical current to drive the electrolytic reaction that deposits pure lead at the cathode, eliminating the need for fuel combustion and high-temperature equipment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the harmful lead-containing waste paste from lead acid batteries into a valuable resource. The electrolytic process transforms the lead compounds in the paste into pure metallic lead through controlled electrochemical reduction, turning an environmental hazard into a recoverable material

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If existing electrolytic approaches are used with acidic electrolyte, then lead can be deposited at the cathode, but the deposited lead re-dissolves when current is discontinued

Engineering Contradiction:

Improvelead depositionVSAvoidlead deposit stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the chemical parameter of the electrolyte from acidic to alkaline composition. This fundamental parameter change alters the chemistry of lead deposition and stabilization, allowing lead to form stable compounds in the alkaline environment that prevent re-dissolution when the current is stopped

Inventive Principle:

Principle #35Parameter changes

4Productivity

If existing electrolytic approaches are used, then lead recovery is attempted, but insoluble lead dioxide forms at the anode limiting current flow

Engineering Contradiction:

Improvelead recoveryVSAvoidcurrent flow

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent changes the chemical parameter of the electrolyte from acidic to alkaline composition. This fundamental parameter change alters the chemistry of lead deposition and stabilization, allowing lead to form stable compounds in the alkaline environment that prevent re-dissolution when the current is stopped

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method enables the scalable, cost-effective, and environmentally friendly recovery of near-pure lead from recycled lead acid batteries, reducing operational costs and environmental impact while achieving high purity levels without the need for high-temperature smelting.

Implementation Method 1

performing solid-state electrolysis on the slurry to form target metal deposits and residual components

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Implementation Method 2

melting the target metal deposits and drawing off dross such that the remaining melted target metal is near-pure

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20240093398A1Electrolytic extraction of elemental metal from metal compounds

Publication Date: 2024.03.21 VERDEEN CHEMICALS INC

AI summary

Disclosed are solutions for the recovery of elemental metals at industrial scales without smelting including, for example, the recovery of near-pure lead from recycled LABs via specialized electrolytic processing. Further disclosed are new processes, innovative electrolyzer designs, and/or novel utilization of supplemental chemicals necessary for successful electrolysis of pure metal from impure forms (e.g., pure lead from lead oxides), and especially applicable for solid-state electrolysis of mixtures comprising lead paste, electrolyte, and supplemental chemicals. With particular regard to recovering near-pure lead during LAB recycling, solid-state electrolysis of mixtures comprising impure lead (e.g., lead paste) is made possible by electrolytic processing using supplemental chemicals, and made scalable to industrial levels via utilization of an horizontal cathode in the electrolyzer.