Reduction in toxicity and generation of slag in secondary lead process

This paper focuses on the improvement of a secondary lead recycling processing plant, giving special attention to the generation of lead slag. The study was conducted using two different industrial rotary furnaces that together produce three different slag types, which depend on charge composition and lead-containing raw material obtained from a lead-acid battery recycling process. First, characterization of three slag types from different batches was performed, and such characterization included chemical, mineralogical, and structural analyses. By analyzing these data and the operational conditions of the process, it was possible to identify certain deficiencies in the recycling process and implement modifications in order to improve it. A reduction of up to 25% in the quantity of slag generated could be achieved with certain charges. In addition to this process improvement, it was possible to reduce the toxicity of the slag produced when processing a charge containing the same proportion of paste and grid as the lead-acid battery. This improvement lessens the overall environmental impact of the process. By applying this methodology, it was possible to determine some principles of cleaner production in the lead recycling process. So, waste generation could be reduced via improvements in the process and slag characteristics were modified to decrease its toxicity (as determined by lead content in leaching tests).