Lead Battery Grid Alloy Preparation with Molten Salt Rare Earth Electrolysis
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Solution Overview
Problem
The existing methods for preparing lead rare earth alloys result in high energy consumption, significant burning loss, low utilization rate of rare earth metals, and high impurity content, due to the need for high-temperature smelting and the energy-intensive production of rare earth simple substances from oxides.
Innovation Solution
A method involving molten salt electrolysis to produce an aluminum-lanthanum-cerium rare earth mother alloy, followed by vacuum melting to create an intermediate alloy, and then combining this with calcium, tin, and remaining lead to form a grid alloy for lead batteries, utilizing a graphite crucible and molybdenum electrodes, which enhances control over alloy composition and reduces impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature smelting is used to prepare lead rare earth alloy, then the alloy can be produced, but energy consumption increases and burning loss occurs
Solution Approach 1:
The patent changes the temperature parameter from high-temperature smelting (600-900°C) to low-temperature molten salt electrolysis (400-500°C), dramatically reducing energy consumption while maintaining alloy production capability. This parameter change resolves the contradiction between reliable alloy production and high energy consumption.
Solution Approach 2:
The patent replaces the thermal-mechanical smelting process with an electrochemical process (molten salt electrolysis). This substitution eliminates the need for high-temperature heating and directly produces the alloy through electrical energy-driven chemical reactions, reducing energy consumption and avoiding burning loss.
2Reliability
If high-temperature smelting is used to prepare lead rare earth alloy, then the alloy can be produced, but burning loss of rare earth metals increases
Solution Approach 1:
By changing the temperature parameter from high (600-900°C) to low (400-500°C) and switching from oxidative smelting to electrolytic reduction, the patent prevents rare earth metal oxidation and burning loss while maintaining alloy production.
Solution Approach 2:
The molten salt electrolysis process creates an inert chemical environment that prevents rare earth metals from oxidizing or burning during the alloy formation process, eliminating substance loss while maintaining production reliability.
3Ease of manufacture
If direct smelting of rare earth metals is used, then alloy preparation is simplified, but impurity content increases
Solution Approach 1:
The patent introduces molten salt as an intermediary medium that enables controlled electrolytic synthesis of the alloy. This intermediary process allows for precise control of composition and impurity levels while maintaining manufacturing feasibility, resolving the contradiction between process simplicity and product purity.
4Ease of manufacture
If conventional smelting method is used, then production process is straightforward, but utilization rate of rare earth metals decreases
Solution Approach 1:
Replacing conventional smelting with molten salt electrolysis transforms an inefficient material utilization process into a highly efficient one, where rare earth metals are directly reduced and incorporated into the alloy with minimal loss, achieving over 90% utilization rate.
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 achieves a higher utilization rate of rare earth metals (>90%) with lower impurity content, reducing energy consumption and improving the uniformity and controllability of alloy components, resulting in improved performance and stability of the lead battery grid alloy.
Implementation Method 1
preparing an aluminum-lanthanum-cerium rare earth mother alloy by using a molten salt electrolysis method
Implementation Method 2
melting the aluminum-lanthanum-cerium rare earth mother alloy with sodium and partial lead
Data Source
AI summary
A method for preparing a grid alloy of a lead battery, comprising the following steps: (1) preparing an aluminum-lanthanum-cerium rare earth mother alloy by using a molten salt electrolysis method; (2) melting the aluminum-lanthanum-cerium rare earth mother alloy with sodium and partial lead and uniformly stirring same to prepare an intermediate alloy; and (3) melting the intermediate alloy with calcium, tin and remaining lead and uniformly stirring same to form a grid alloy of a lead battery.