The Lead Refining Process: Turning Waste into High-Quality Resources
At EL BAT, our dedication to sustainability and the circular economy is embodied in a refined lead production process that turns used lead-acid batteries into valuable, high-purity materials. Through an efficient and environmentally responsible three-stage system, we recover resources while minimizing waste.
Battery Collection & Separation
The process begins with the collection and dismantling of spent lead-acid batteries—a rich source of recyclable components. During this phase:
- Batteries are mechanically separated into three main elements: lead-bearing materials, sulfuric acid, and plastic casings.
- Sulfuric acid is neutralized or further processed for reuse.
- Plastic components are cleaned and prepared for recycling—often used again in battery casings or other plastic applications.
This stage ensures a clean and efficient input stream for the next steps in the refining process while significantly reducing waste from the outset.
Lead Smelting in Short Rotary Furnaces
Separated lead components are transferred to high-efficiency short rotary furnaces (SRFs) where the transformation truly begins:
- Scrap lead is melted at controlled high temperatures
- Impurities are removed through fluxing and chemical reactions.
- The output is crude lead, also known as soft lead bullion.
Our SRFs are equipped with advanced filtration and gas scrubbing systems that capture emissions and ensure full compliance with stringent environmental regulations.
Lead Refining in Refinery Kettles
In the final stage, the remelted lead undergoes a meticulous refining process in large, temperature-controlled kettles to achieve international quality standards:
- Trace elements such as copper, antimony, and arsenic are removed.
- Depending on application needs, specific alloying elements are added to create customized lead alloys.
- The final product is 99.97% to 99.99% pure refined lead, suitable for use in new batteries, cable sheathing, radiation shielding, and more.
Polypropylene Recycling: Giving New Life to Battery Plastics
Lead is not the only valuable material recovered from used batteries. The polypropylene (PP) used in battery casings is also repurposed through our high-efficiency, environmentally conscious plastic recycling process.
1. Separation of Polypropylene
During battery dismantling, plastic components—mainly PP—are mechanically separated from the lead and acid:
- Contaminants such as sulfuric acid and lead particles are eliminated.
- The remaining plastic is shredded into uniform polypropylene chips, preparing it for purification.
2. Washing and Purification
The chips then undergo a multi-stage intensive washing process using hot water, detergents, and high-speed friction separators to remove:
- Residual battery acid
- Trace metals and contaminants
- Organic particles and dirt
This ensures a clean and compliant plastic feedstock for extrusion.
3. Extrusion and Pelletizing
The purified polypropylene chips are melted and processed in an advanced extrusion system:
- Inside the extruder, the plastic is homogenized and filtered.
- If needed, additives are blended to enhance performance.
- The material is shaped into strands, cooled, and cut into uniform PP granules.
These high-quality pellets are ready for reuse in the production of:
- New battery casings
- Automotive parts
- Packaging materials
- Consumer goods
Environmental Stewardship: In-House Sewage and Wastewater Treatment
EL BAT is deeply committed to environmental safety. All our recycling and smelting operations are supported by on-site wastewater treatment systems, ensuring that process water is safely treated, recycled, or discharged according to strict environmental standards.
Why It Matters
Battery dismantling, lead smelting, and polypropylene washing generate wastewater that may contain:
- Acidic residues from sulfuric acid neutralization
- Heavy metals such as lead, arsenic, and antimony
- Plastic contaminants and suspended solids
If untreated, these pose serious environmental and regulatory risks.
1. Collection and Segregation
Each wastewater stream is:
- Collected separately based on its origin (battery separation, smelting, plastic washing, etc.)
- Categorized by chemical and physical characteristics, preventing cross-contamination and protecting natural water sources
2. Neutralization and Chemical Treatment
Treatment starts with:
- pH neutralization, especially for acidic water
- Chemical precipitation of heavy metals using lime, caustic soda, or sulfides
- Coagulation and flocculation to bind suspended solids into a separable form
3. Filtration and Sedimentation
Following chemical treatment:
- Water passes through sedimentation tanks and filtration units to remove solids and remaining pollutants
- Sludge is collected and either safely disposed of or prepared for material recovery
4. Reuse in Circular Water Systems
Where possible, treated water is reused within our facility for:
- Cooling systems
- Washing polypropylene chips
- Furnace cleaning
This significantly reduces freshwater consumption and supports our zero-waste production goals.
Our Promise: No Compromise on Environmental Safety
Every treatment plant is monitored around the clock, and all emissions and discharges meet or exceed international standards. We invest continuously in best-in-class technologies to ensure:
- No untreated water enters the environment
- Emissions are minimized
- Our operations remain safe, compliant, and sustainable
Clean water. Clean materials. Clean future.
It’s not just a system—it’s our principle.
