Integrated Solution for Battery Crushing and Sorting + Oxygen-Enriched Smelting + Flue Gas Treatment

The rapid growth of lead-acid battery usage in automotive, industrial, and energy storage applications has led to an urgent need for safe and sustainable battery recycling systems. However, recycling spent batteries involves multiple stages—each presenting environmental, technical, and operational challenges.

To address these challenges, RE TECH offers a fully integrated solution that combines three critical systems:

1. Battery Crushing & Sorting

2. Oxygen-Enriched Smelting

3. Flue Gas Treatment

This article explores how this integrated approach not only simplifies plant operations but also ensures compliance with the world’s most stringent emission standards.

Why an Integrated Recycling Line Matters

Traditional battery recycling plants often rely on disconnected systems sourced from multiple suppliers. This approach leads to:

• Process mismatches between stages

• Inefficient energy usage

• Difficulties in automation and centralized control

• Higher emissions and environmental risks

An integrated solution, in contrast, enables smooth transitions between stages, optimized energy use, and complete environmental control. It’s also easier to scale, maintain, and operate with minimal manual intervention.

Stage 1: Battery Crushing and Sorting

The recycling process begins with safe, enclosed crushing of used lead-acid batteries to separate key components:

• Lead paste

• Lead grids

• Plastic casings

• Electrolyte

RE TECH’s automatic crushing and separation systems ensure:

• Zero acid leakage

• High separation accuracy

• Safe handling of hazardous materials

• Low noise and dust generation

The output from this stage feeds directly into the smelting system, with minimal material loss and preparation time.

Stage 2: Oxygen-Enriched Side-Blowing Smelting

Once sorted, lead-bearing materials are fed into RE TECH’s advanced OSBF system, which uses oxygen enrichment and horizontal lance injection to:

• Achieve fast melting and high lead recovery (>98%)

• Reduce the amount of excess air, lowering total flue gas volume

• Maintain stable furnace temperature and efficient slag formation

• Handle a wide range of feedstock types, including lead paste, slag, and recycled materials

The OSBF’s closed system also improves operator safety and minimizes fugitive emissions.

Stage 3: Integrated Flue Gas Treatment

Flue gas from the smelting stage contains lead dust, SO₂, and other pollutants that must be treated before release. RE TECH’s modular gas purification line includes:

• Cyclone dust collectors + bag filters or ESP

• Wet or semi-dry flue gas desulfurization (FGD)

• Optional NOx control systems (e.g., SCR)

• Real-time emission monitoring

These systems ensure that flue gas meets or exceeds standards such as:

• China’s GB 25467-2010

• EU Industrial Emissions Directive

• US EPA NESHAP regulations

Typical emission performance includes:

• Lead dust: ≤1 mg/Nm³

• SO₂: ≤100 mg/Nm³

• NOx: optional treatment to <200 mg/Nm³

Centralized Control & Automation

All systems in RE TECH’s integrated solution are managed via a centralized PLC/SCADA system, offering:

• Real-time data collection

• Alarm and fault diagnosis

• Remote control and adjustment

• Full production traceability

This allows plant operators to maintain high efficiency and environmental compliance with minimal staffing.

Advantages of the RE TECH Integrated Solution

Turnkey EPC Delivery — Design, engineering, manufacturing, installation, and commissioning handled by one expert provider.

Full Process Compatibility — Crushing, smelting, and purification systems are designed to work as one coherent unit.

Reduced Operating Costs — Higher recovery rates and energy optimization lower cost per ton of lead produced.

Environmental Compliance — Emissions kept below national and international limits, ensuring long-term legal and reputational security.

Customized to Client Needs — Modular and scalable designs accommodate plant sizes from small-scale to 50,000+ tons/year capacities.

Conclusion

As battery consumption continues to rise worldwide, environmental regulators are placing tighter restrictions on recycling processes. Smelters must now go beyond just recovery—they must demonstrate full-chain environmental responsibility.

RE TECH’s integrated solution, combining battery crushing and sorting, oxygen-enriched smelting, and flue gas treatment, offers a proven, scalable, and compliant path forward. With successful deployments across Asia, Africa, and South America, RE TECH is ready to help global recyclers modernize their operations and lead in the circular economy.