Our Process

Breaking and separation

CX System - Fully automated battery crushing and hydro separation

Our state-of-the-art battery breaking and separation plant utilizes specialized machinery to process the delivered battery scrap with precision. The batteries are first loaded into the feeding and metering system, which directs them to a crushing mill for size reduction. The material is then separated into two main streams using our advanced separation equipment: one for the lead paste and the other for the coarse metallic fraction (grids and posts).

The leadpaste slurry is pumped to a filter press for dewatering. The metallic fraction undergoes further separation, with the fine-sized fraction (grids and Pb-Ca) and coarse fraction (posts and Pb-Sb) sorted using dedicated sorting equipment. The CX System efficiently manages the separation of various materials, ensuring they are discharged into appropriate areas for further processing.

Smelting

High-performance smelting furnace

The smelting process utilizes highly specialized smelting furnace for an efficient and controlled procedure. Lead-based materials are processed in fixed-axis rotary furnaces, which are equipped with oxygen-fuel burners to boost combustion efficiency and temperature control.

The charging system consists of automated materials metering and feeding unit, designed for precise and consistent material input into the furnace. This system ensures uniform material loading and optimized processing parameters. To control particulate emissions and ensure compliance with environmental standards, the furnace is fitted with a dedicated flue gas treatment system.

Refining and alloying

High-tech refining section

The raw lead produced in the rotary furnaces is further processed in kettles under controlled procedures and temperatures to remove impurities and foreign metals. This refining process aims to produce refined lead and various alloys required by the market. The operation involves the use of essential ancillary equipment, including pumps for material transfer, agitators for stirring and mixing, dross removers for impurity extraction, and oxygen injectors to enhance chemical reactions during refining.

The final products are then cast into ingots using a dedicated automatic casting line, equipped with stacking systems to automate the packaging process.

Refined lead and lead alloys

Fully equipped laboratory

Our state-of-the-art laboratory features the latest instrumentation designed for precise analysis of materials and impurities in lead metal. This ensures the consistent production of high-purity refined lead and specialized lead alloys with superior process control. Its advanced analytical capabilities are integral for maintaining stringent quality standards throughout every stage of production. Key instruments include:

Key instruments include:

• Optical emission spectrometer (OES):

  Provides accurate multi-elemental analysis of the metal composition

• Atomic absorption spectrometer (AAS):

  Detects trace elements and impurities in lead with high sensitivity

• Advanced sample preparation equipment:

  Ensures accurate preparation and homogenization of samples prior to analysis

New Lead Acid Battery

Return to supply chain for industrial use

The high-purity lead (99.985%) and alloys produced through our advanced recycling process are used by our customers for the manufacturing of new lead-acid batteries, extending the lifecycle of materials and supporting a circular economy.