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WO2025102139A1 - Procédé pour la récupération de fer et de plomb à partir d'une scorie de four de pré-traitement de composants de batteries plomb-acide - Google Patents

Procédé pour la récupération de fer et de plomb à partir d'une scorie de four de pré-traitement de composants de batteries plomb-acide Download PDF

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Publication number
WO2025102139A1
WO2025102139A1 PCT/BR2024/050520 BR2024050520W WO2025102139A1 WO 2025102139 A1 WO2025102139 A1 WO 2025102139A1 BR 2024050520 W BR2024050520 W BR 2024050520W WO 2025102139 A1 WO2025102139 A1 WO 2025102139A1
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WIPO (PCT)
Prior art keywords
lead
furnace
slag
iron
acid battery
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/BR2024/050520
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English (en)
Portuguese (pt)
Inventor
Charles DUPOND
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Individual
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Individual
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Filing date
Publication date
Priority claimed from BR102024023602-5A external-priority patent/BR102024023602A2/pt
Application filed by Individual filed Critical Individual
Publication of WO2025102139A1 publication Critical patent/WO2025102139A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B7/00Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
    • C22B7/04Working-up slag
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B13/00Obtaining lead
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22BPRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B13/00Obtaining lead
    • C22B13/02Obtaining lead by dry processes

Definitions

  • the present invention patent refers to a process that may be continuous or not, in a blast furnace, cupola type furnaces or similar for the recovery of iron and lead from lead-acid battery slag, applicable in the area of metallurgy and steelmaking, specifically in the metalworking industry for the recovery of iron, lead and other metals, with the objective of minimizing the disposal of these metals in landfills through recycling, enabling a more noble destination for this raw material, with the advantages of protecting water resources and soil against leaching and reducing the costs associated with the supply of iron and lead for battery recycling.
  • Lead-acid battery recovery processes currently use pre-processing furnaces for the components of these batteries, which mostly generate high concentrations of pollutants and slag with high concentrations of impurities and heavy metals such as lead.
  • the metallurgical, steel and metalworking industries lack effective and sustainable ways to reuse or dispose of this slag in a more noble way, and it is commonly discarded in landfills.
  • metals such as iron, lead, manganese, zinc, copper, tin and antimony can leach out, causing contamination of soil and water systems.
  • Lead is a highly toxic metal that can cause illness and even death in living organisms. In humans, prolonged exposure to lead can lead to accumulation in the body, affecting the brain, circulatory system, kidneys, digestive and reproductive systems, and can also cause genetic mutations in future generations. This metal is dispersed in the environment, contaminating soil, water and air, especially through inadequate disposal practices and industrial emissions, representing a major risk to public health and the environment, which requires rigorous waste management practices.
  • Korean patent KR102412921B1 describes a process for recovering lead from used batteries using a rotary kiln. This method involves pre-processing the battery components, including the lead paste and grid. A mixture of at least 20% by total weight of a carbon source, an iron source, a sodium source and a calcium source is then added to the lead source material before being fed into the rotary kiln for smelting.
  • Korean patent KR101108236B1 presents an automated system for extracting and refining lead from batteries.
  • the steps performed by the equipment include: extraction of residual acid; grinding; separation and; smelting. Initially, the device removes the acid from the battery and grinds it into pieces. The separation of the substrates is carried out by difference in densities. The extracted paste is neutralized before being melted together with the recovered lead in a device that combines the mixing, melting and refining phases, in the automated process.
  • the patent fulfills the objective of recycling lead, it uses wet electrolysis, which has several disadvantages in this process, such as high energy consumption, pH control and high temperature.
  • chlorine gas is generated, which is much more dangerous to health and the atmosphere.
  • the wear of the electrodes may require additional treatment steps, which can increase the time, cost and efficiency of the process.
  • Chinese patent CN115161489A discloses a process for producing lead alloys from waste lead-acid battery cases.
  • One of the objectives of this invention is to solve the problem of copper contamination in lead alloy.
  • the process involves crushing, grinding and refining the battery grids, facilitating the fusion and reaction with the copper removal agent, resulting in a lead alloy with low levels of impurities.
  • Chinese patent CN111778415 A discloses a method for preparing a slag reducing agent based on battery production sludge. The process involves pumping the sludge and residues from wastewater treatment into a sludge tank, where they are agitated and subsequently pressed in a filter to form a filter press sludge rich in inorganic matter. This sludge acts as a reducing agent, recovering large amounts of lead and minimizing slag formation.
  • Chinese patent CN107312946B presents a slag subtraction agent for battery grids, composed of CaCCh, charcoal, sawdust, borax and sodium carbonate. The purpose of applying these components is to minimize the oxidation of liquid lead, limiting slag formation to 2.5 - 2.9%, segregating the substrates and decreasing lead loss.
  • Chinese patent CN113621810 aims to provide a lead ingredient and preparation method for regenerating and reducing waste lead-acid batteries and lead-containing waste materials, using the battery component pre-processing furnace itself to reduce the cost of regenerating and reducing waste lead-acid batteries and lead-containing waste materials.
  • Return slag refers to the bottom slag containing iron and lead left over from previous smelting furnaces. This solution realizes the reuse of return slag by adding part of the return slag to reduce the melting point of the overall slag, saving energy and playing a role in slag manufacturing and reducing the amount of iron filings used in slag manufacturing.
  • the patent process mentions replacing iron filings or chips with pyrite iron ore slag, that is, it is not just lead slag.
  • the waste used for recovery is: metal battery components plus lead scrap; the furnace used is a short drum rotary furnace; and the slag obtained after smelting consists of sodium and iron sulfide, which are chemically processed by acid-base reactions, which generate salts and water, which are undesirable in the process because they contribute to the oxidation of the materials to be recovered, which does not occur, unlike the process of this patent.
  • the patent presents a process focused on environmental regulations, the complexity and several stages of the process such as leaching, oxidation, decantation and filtration can increase the costs and energy used in the process, in addition to the risks of contamination involved in these stages.
  • PROCESS FOR RECOVERING IRON AND LEAD FROM SLAG FROM PRE-PROCESSING FURNACE OF LEAD-ACID BATTERY COMPONENTS object of this patent, aims to solve the limitations and disadvantages of the methods currently used for recycling and recovering iron and lead and other metals, promoting a more efficient and environmentally safe recycling of the metallic residues present in the slag of lead-acid batteries.
  • the present invention relates to an innovative process for recycling iron, lead and other elements from the disposal of lead slag.
  • This process is structured in stages that use reverse logistics to transform ferrous lead slag into mainly lead and iron that can be reused in the recycling of lead/acid batteries.
  • the proposed methodology aims to minimize the amount of environmentally aggressive metals, reducing disposal in landfills and offering an environmentally friendly method for lead recovery, contributing significantly to the reduction of environmental contamination.
  • the advantages of the process of this patent are the following: protection of water resources for future generations who may pay the high price of water tables and soil completely contaminated by leaching; reduction of costs associated with the supply of iron and lead for battery recycling; recycling of lead slag from the smelting of pre-processing of lead-acid battery components; reduction of raw material costs for the slag generators themselves who will have iron and lead reused, generating a reduction in the high costs of iron for recycling batteries and more noble metals.
  • Contaminated cast iron because it contains other noble metals, is still discarded in landfills, worsening the environmental liability.
  • This patent solves this problem through a secondary process that transforms contaminated cast iron into a reusable ferrous alloy, at levels above 95% of concentrated iron, which can be returned to the pre-processing furnace, replacing the iron chips, establishing circular recycling and reverse logistics or even for the metalworking industry;
  • Figure 1 illustrating the schematic representation of the steps, substrates, parameters and equipment involved in the process for reusing slag of the present patent - separation by ingots;
  • Figure 2 illustrates the schematic representation of the steps, substrates, parameters and equipment involved in the alternative process for reusing slag of the present patent - atomization
  • Figure 3 illustrating: (A) Granulated sample in receiving state; (B) Sample melted with an oxyacetylene torch and resolidified;
  • Figure 4 illustrating: (A) Base of the electric arc furnace before melting the samples; (B) Base of the electric arc furnace after melting the samples;
  • Figure 5 illustrating the powder sample after being subjected to the electric arc in the electric arc furnace
  • Figure 6 illustrates the granulated sample after being subjected to the electric arc in the electric arc furnace.
  • the present invention describes a process for the continuous or discontinuous reuse of slag (3.1) from lead-acid batteries in a smelting furnace (1), such as a blast furnace, cupola furnace or similar, while maintaining strict control of the temperature and purity of the reused substrates.
  • a smelting furnace (1) such as a blast furnace, cupola furnace or similar
  • the furnace (1) initially preheated, is uniformly charged with coke (2), and a mixture (3) of slag (3.1) from lead-acid batteries with flux (3.2), forming the basis for processing;
  • the coke (2) and the mixture (3) are added through the loading mouth (1.1) in alternating layers, creating a controlled environment where the material is uniformly heated through the entry of air into the nozzles (1.2), melting and descending by gravity inside the furnace (1).
  • the temperature in the furnace (1) is strictly maintained between 888°C and 1700°C, since lead boils at 1749°C, and for safety reasons the furnace (1) has a gas scrubber (7) containing a collection duct (7.1), lower opening (7.2), filling with neutralizing chemicals (7.3) and exhaust fan (7.4) to prevent contamination of the factory environment;
  • the metals begin to liquefy according to their melting points.
  • the liquid metals are segregated by differences in density, with the lead (4) and the ferrous alloy (5) being extracted in the lower spout (1.4) and the residual slag (6) begins to liquefy according to the melting points of its constituents and is extracted in the upper spout (1.3) of the furnace (1);
  • the lead (4) and the ferrous alloy (5) are fed into two sequential uneven pans (8) that decant the lead and the evaporated contaminants are directed to the lower opening (7.2) of the gas scrubber (7);
  • the ingots (9) with a lower layer of lead (4) with an upper layer of ferrous alloy (5), after cooling, both are separated by means of longitudinal cuts with a saw (10), so that the longitudinal cuts are made at a safe height to avoid contamination of lead (4) in the ferrous alloy (5) in a proportion greater than that permitted by law;
  • Lead (4) is directed to the lead-acid battery industry or for processing or use in the metallurgical industry;
  • the ferrous alloy (5) with a qualitative composition of iron, tin, copper, zinc, manganese and maximum antimony and lead within the legislation is intended for processing or use in the metal-mechanical industry; and
  • the residual slag flow (6) separated from the upper spout (1.3) is directed to a patio for cooling in the ambient air and can be sent to other industrial sectors, such as cement production, as long as it contains levels of contaminants such as lead (4) within those permitted by law.
  • the separation of iron and lead alloys may occur in the following sequence, according to Figure 2: a.l
  • the furnace (1) initially preheated, is uniformly loaded with coke (2) and a mixture (3) of slag (3.1) from lead-acid batteries with flux (3.2), forming the basis for processing; b.l
  • the coke (2) and the mixture (3) are added through the loading mouth (1.1) in alternating layers, creating a controlled environment where the material is uniformly heated through the entry of air into the nozzles (1.2), melting and descending by gravity inside the furnace (1).
  • the temperature in the furnace (1) is strictly maintained between 888°C and 1700°C, since lead boils at 1749°C, and for safety reasons the furnace (1) has a gas scrubber (7) containing a collection duct (7.1), a lower opening (7.2), a filling with neutralizing chemicals (7.3) and an exhaust fan (7.4), preventing contamination of the factory environment; d.l Inside the furnace (1), the metals begin to liquefy according to their melting points.
  • the liquid metals are segregated by differences in density, with the lead (4) and the ferrous alloy (5) being extracted through the lower spout (1.4) and the residual slag (6) beginning to liquefy according to the melting points of its constituents and being extracted through the upper spout (1.3) of the furnace (1); e.1
  • the liquid flow of lead (4) and ferrous alloy (5) are fed into a channel (11)
  • the evaporated contaminants are directed to the lower opening (7.2) of the gas scrubber (7) and downstream the liquid flow leaves the channel (11) through the opening thereof forming a cascade that receives atomization (12) through a lower jet of water or gases that cool the metals forming iron chips with lead (13); and f.l
  • the flow of residual slag (6) separated from the upper spout (1.3) is directed to a yard for cooling and can be forwarded to other industrial sectors, such as cement production, as long as it contains levels of contaminants such as lead (4) within the levels permitted by legislation.
  • the first batch of granulated slag samples was melted using a blowtorch fed with a mixture of oxygen and acetylene. This mixture was chosen because it produced a flame with a temperature of up to 3,200°C, thus ensuring the fusion of all compounds present in the sample.
  • the sample melted easily under the acetylene and oxygen flame. However, apparently, the bonds of the compounds, or at least of most of the compounds present, were not broken to release the metallic elements. As a result, the molten sample resolidified into fragments, appearing solid in a manner very similar to its initial state.
  • the second batch of granulated sample was melted in an electric arc furnace (EAF) under an argon atmosphere. Since the position of the electric arc in the AEF is manually adjusted, it was difficult to move the arc over the sample, as it dispersed a lot of powder (and possibly gases) during its melting, obscuring the furnace chamber and blackening its entire interior with fine particulate matter, as can be seen in Figure 4.
  • EAF electric arc furnace
  • the powder sample did not react as expected to the electric arc and remained in powder form after the FEA process, in a condition very similar to that upon receipt, as shown in Figure 5. It is even possible that the electric arc dispersed the powder particles throughout the EAF chamber, and a sintering or pelletizing process may be necessary to better work with the powder samples.
  • the granulated sample performed better in the EAF, melting under the action of the electric arc and resolidifying according to the geometry of the cavity in the EAF base, instead of fragmenting during solidification as occurred in the process with the oxyacetylene torch.
  • Figure 6 shows the granulated sample after melting in the EAF, where it can be seen that it has a brighter appearance, very similar to hematite. Furthermore, when sanded with the grinding wheel, the sample presented a very metallic shine. We can state that this process did not result in the formation of metal, as desired, due to the low density of the final compound and its brittleness. As seen in Figure 6, the material is fragmented, and this fracture occurred under very low tension (the sample was flexed manually).
  • the slag (3.1) from lead-acid batteries is a complex material, and the analysis of its thermal and melting behaviors, performed with an acetylene torch and FEA, was essential to understand how the slag would react to different heat sources and how the materials could be separated efficiently. These tests provided valuable information about the temperature required for complete melting of the compounds, the difficulties encountered when trying to melt the sample in different forms (granular and powder), and how to adjust the temperature and melting time variables to optimize the process.
  • the results obtained in the initial laboratory tests can be applied to larger capacity furnaces, such as blast furnaces and cupola furnaces, adapting the process to different industrial equipment, which guarantees the viability of the process on a large scale. Based on these observations, we carried out new tests in a pit-type furnace, simulating the blast furnace or cupola furnace.
  • the process was carried out with a well-type furnace, simulating the supply layers of a cupola furnace, maintaining maximum temperatures between 1,686°C and 1,700°C, respecting this temperature due to the boiling point of lead being 1,749°C.
  • the coking coal reduced the oxides and melted the metals, which, in the liquid phase, flowed between the coke fragments, accumulating at the bottom of the well-type furnace.
  • the flux (3.2) contributed to the removal of impurities to the slag (3.1).
  • Limestone derived from the flux, decomposed into calcium oxide (CaO) and carbon dioxide (CO2) at high temperatures.
  • the CaO then reacted with acidic impurities in the slag (3.1) from the recycling process, such as silica (SiO2), forming the slag with a base composition of calcium silicate CaSiOi.
  • the most suitable process for obtaining metals from the samples provided would be through a cupola furnace (1).
  • This furnace (1) uses coking coal (2) and the granulated, sintered or pelletized samples are placed under the coal, which, when incandescent, provides heat to melt the samples and carbon to reduce the metallic compounds.
  • Table 1 most of the iron, zinc, copper, manganese, tin, antimony and lead can be easily obtained by this process, while other compounds are volatilized or removed together with the residual slag (6).
  • the purifications and separations achieved showed a purity of the recovered lead (4) above 81.0%, and the residual contamination of toxic metals at minimal levels, illustrating the effectiveness of the new methodology.
  • the optimized process not only stands out in terms of technical performance, but also offers a more sustainable and economical approach to the reuse of noble and/or toxic metals.
  • this concentration is higher than the legislation, this residual slag (6) is sent to landfills in reduced volumes, minimizing toxicity and environmental impact.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Environmental & Geological Engineering (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

L'invention concerne un procédé de réutilisation continue ou discontinue de la scorie (3.1) de batteries plomb-acide dans un four (1) de fusion, tel qu'un haut-fourneau, un cubilot ou analogues, assurant un contrôle rigoureux de la température et de la pureté des substrats réutilisés avec récupération du fer (5) et du plomb (4) à partir d'une scorie (3.1) de batteries plomb-acide, trouvant une application dans le domaine de la métallurgie et de la sidérurgie, notamment dans l'industrie métallo-mécanique pour la récupération de fer (5), de plomb (4) et d'autres métaux, par recyclage inverse, y compris avec réhabilitation de décharges, d'où une destinée plus noble pour cette matière première, avec des avantages tels que la protection des ressources hydriques et du sol contre la lixiviation et la diminution des coûts associés à la fourniture de fer (5) et de plomb (4) dans le cadre du recyclage de batteries.
PCT/BR2024/050520 2023-11-13 2024-11-13 Procédé pour la récupération de fer et de plomb à partir d'une scorie de four de pré-traitement de composants de batteries plomb-acide Pending WO2025102139A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
BR1020230238009 2023-11-13
BR102023023800 2023-11-13
BR1020240236025 2024-11-12
BR102024023602-5A BR102024023602A2 (pt) 2024-11-12 Processo para recuperação de ferro e chumbo a partir de escória de forno de pré-processamento de componentes de baterias de chumbo-ácido

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WO2025102139A1 true WO2025102139A1 (fr) 2025-05-22

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3679395A (en) * 1970-07-27 1972-07-25 Us Smelting Refining & Mining Process for recovering lead,lead alloys,and lead compositions from batteries
CN102965509A (zh) * 2012-11-27 2013-03-13 中南大学 处理废铅酸蓄电池胶泥与富铁重金属固废的方法及设备
US9435005B2 (en) * 2012-04-16 2016-09-06 Outotec (Finland) Oy Method for processing slags of non-ferrous metallurgy
CN113621810A (zh) * 2021-08-12 2021-11-09 尤全仁 一种废铅酸蓄电池及含铅废料再生还原铅配料及制备方法
CN115976333A (zh) * 2022-11-22 2023-04-18 云南驰宏锌锗股份有限公司 一种热渣侧吹还原炉的冶炼方法

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3679395A (en) * 1970-07-27 1972-07-25 Us Smelting Refining & Mining Process for recovering lead,lead alloys,and lead compositions from batteries
US9435005B2 (en) * 2012-04-16 2016-09-06 Outotec (Finland) Oy Method for processing slags of non-ferrous metallurgy
CN102965509A (zh) * 2012-11-27 2013-03-13 中南大学 处理废铅酸蓄电池胶泥与富铁重金属固废的方法及设备
CN113621810A (zh) * 2021-08-12 2021-11-09 尤全仁 一种废铅酸蓄电池及含铅废料再生还原铅配料及制备方法
CN115976333A (zh) * 2022-11-22 2023-04-18 云南驰宏锌锗股份有限公司 一种热渣侧吹还原炉的冶炼方法

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
"Projeto Santo Amaro - BA: aglutinando ideias, construindo soluções - diagnósticos", 1 January 2012, CETEM/MCTI, Rio de Janeiro, ISBN: 978-85-61121-94-5, article LUIS GONZAGA DOS SANTOS SOBRAL, DÉBORA MONTEIRO DE OLIVEIRA, CARLOS EDUARDO GOMES DE SOUZA, SILVIA CRISTINA ALVES FRANÇA SILVA, PA: "Metalurgia do chumbo: processos de produção e refino", pages: 150 - 173, XP009563699 *
PAN DE’AN; LI LILI; TIAN XI; WU YUFENG; CHENG NA; YU HAILIANG: "A review on lead slag generation, characteristics, and utilization", RESOURCES, CONSERVATION AND RECYCLING, ELSEVIER, AMSTERDAM, NL, vol. 146, 1 January 1900 (1900-01-01), AMSTERDAM, NL , pages 140 - 155, XP085671144, ISSN: 0921-3449, DOI: 10.1016/j.resconrec.2019.03.036 *

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