Lead-Acid Battery Recycling Plant for Fiber Separation and Drying
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Solution Overview
Problem
Existing lead-acid accumulator treatment processes are inefficient in terms of quantity and quality of secondary raw materials recovered, with issues such as sieve clogging and contamination from glass and textile fibers, and high residual moisture in separated fractions.
Innovation Solution
A treatment plant and process that includes a grinder, multiple separator devices with sieves, pressurized water injection to detach fibers, and compressed air diffusion to reduce moisture, combined with flocculant use to enhance separation efficiency and quality of recovered materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separator devices with sieves are used to separate ground heterogeneous material, then separation of materials is achieved, but sieve clogging occurs due to glass and textile fibers
Solution Approach 1:
The harmful glass and textile fibers are extracted from the material stream before reaching the sieve, using a hydro-separator that leverages density differences to remove these fibers from the ground heterogeneous material, preventing sieve clogging
Solution Approach 2:
A hydro-separator acts as an intermediary device between the grinder and the sieve-based separator, preprocessing the ground heterogeneous material to remove problematic fibers before they can clog the sieve
2Manufacturing precision
If multiple separator devices are used to improve separation quality, then recovery of secondary raw materials is enhanced, but device complexity increases
Solution Approach 1:
The hydro-separator serves multiple functions: it removes glass fibers, removes textile fibers, and prepares material for subsequent separation stages, allowing a single device to perform what would otherwise require multiple specialized devices
Solution Approach 2:
The hydro-separator combines fiber removal and material preparation functions into a single integrated unit that feeds into the existing sieve-based separation system, reducing overall plant complexity while maintaining separation quality
3Quantity of substance
If conventional drying methods are used to reduce moisture in separated fractions, then residual moisture is reduced, but energy consumption increases
Solution Approach 1:
Compressed air is used as a pneumatic drying medium to remove residual moisture from separated fractions, providing an energy-efficient alternative to thermal drying methods while effectively reducing moisture content
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
Enhances the separation and recovery of high-quality secondary raw materials by preventing sieve clogging, reducing moisture, and improving the metallurgical treatment of lead-based materials, thus optimizing the recycling process.
Implementation Method 1
selectively supplying a pressurized water flow against an output face of the sieve
Implementation Method 2
diffusing compressed air onto at least one of said separated fractions
Implementation Method 3
combined with flocculant use to enhance separation efficiency
Data Source
AI summary
A spent and/or decommissioned lead-acid accumulator treatment plant may include: a grinder configured to receive a plurality of spent and/or decommissioned lead-acid accumulators and to output a ground heterogeneous material; and a plurality of separator devices, wherein each of the separator devices is configured to receive a respective input heterogeneous material and to extract therefrom at least two respective output fractions, wherein each of the output fractions is homogeneous or less heterogeneous than the respective input heterogeneous material, wherein the respective input heterogeneous material is the ground heterogeneous material or is one of the at least two respective output fractions of another one of the separator devices. The plant further may include an air pressurizing device and at least one diffuser configured to diffuse compressed air generated by the air pressurizing device onto at least one of the output fractions of the separator devices.