Lead Paste Electrolysis With Horizontal Cathode, No Smelting
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Solution Overview
Problem
Existing electrolytic processes for recovering elemental metals like lead from recycled lead acid batteries are impractical on an industrial scale due to the formation of undesirable side products, high costs, and environmental pollution, particularly from high-temperature smelting, and the inefficiency of current electrode materials.
Innovation Solution
A novel electrolytic system using a horizontal cathode and supplemental chemicals to perform solid-state electrolysis, which includes desulfurization and mechanical separation of lead oxides, allowing for the recovery of near-pure lead without smelting, by combining impure lead paste with an electrolyte to form a slurry, performing electrolysis, and separating the target metal from residual components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing electrolytic processes are used to recover lead from battery paste, then lead recovery is achieved, but insoluble lead dioxide forms at the anode limiting current flow and diminishing operational effectiveness
Solution Approach 1:
The patent changes the chemical parameters of the electrolyte by using a neutral or alkaline electrolyte instead of traditional acidic electrolytes. This parameter change prevents the formation of insoluble lead dioxide at the anode, maintaining stable current flow and operational effectiveness while recovering lead from battery paste
Solution Approach 2:
The patent introduces supplemental chemicals as intermediaries in the electrolytic process. These chemicals mediate the electrochemical reactions to prevent unwanted side reactions that form lead dioxide, thereby maintaining both productivity and reliability of the lead recovery process
2Productivity
If acidic electrolyte is used for lead recovery at the cathode, then lead is deposited, but the lead forms a film on the cathode surface that is difficult to remove and re-dissolves when current is discontinued
Solution Approach 1:
The patent changes the pH parameter of the electrolyte from acidic to neutral or alkaline conditions. This parameter change fundamentally alters the deposition mechanism, producing lead as a porous or spongy structure rather than a dense film, making the deposited lead easy to remove and preventing re-dissolution when current is discontinued
Solution Approach 2:
The patent creates a cathode product (deposited lead) that is intentionally designed to be easily removable and replaceable. The lead deposits in a form that can be simply stripped from the cathode surface, allowing for quick cathode regeneration and continuous operation without complex removal mechanisms
3Productivity
If high-temperature smelting is used for lead recovery, then lead can be recovered from battery paste, but environmental pollution is generated
Solution Approach 1:
The patent replaces the thermal/mechanical smelting process with an electrochemical electrolytic process. Instead of using high-temperature heating to recover lead, the invention uses electrical energy to drive electrochemical reactions that extract lead from battery paste at much lower temperatures, eliminating the harmful emissions associated with smelting
Solution Approach 2:
The patent changes the fundamental operating parameter from high temperature (smelting) to ambient or moderate temperature (electrolysis). This parameter change transforms the recovery process from a polluting thermal process to a clean electrochemical process, maintaining lead recovery capability while eliminating environmental pollution
4Productivity
If electrode materials are used for lead recovery, then electrolytic recovery is achieved, but the electrode materials are relatively expensive
Solution Approach 1:
The patent employs simple, inexpensive electrode materials that can be easily replaced rather than using costly specialized electrodes. The electrodes are designed to be basic conductive materials that perform the electrolytic function adequately and can be replaced cheaply, making the overall process cost-effective despite the consumable nature of the electrodes
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
The system achieves scalable, cost-effective, and environmentally friendly recovery of near-pure lead by minimizing electrode wear, reducing side product formation, and eliminating the need for high-temperature smelting, thereby enhancing operational efficiency and reducing environmental impact.
Implementation Method 1
combining the impure metal material with an electrolyte to form a slurry
Implementation Method 2
performing solid-state electrolysis on the slurry to form target metal deposits and residual components
Data Source
AI summary
To the extent that it should be deemed proper, necessary, or expedient (at the discretion of the Office), please amend the attorney docket number indicated in the header of the Abstract of the present Application as follows:Attorney Docket No.: AGR2202QQ1U