In the bustling streets of Lagos, where the hum of generators and the roar of commercial vehicles fill the air, there's an unseen challenge brewing beneath the surface: the disposal of lead acid batteries. These powerhouses of energy, found in cars, trucks, and backup generators, are a lifeline for Nigeria's growing economy. But when they reach the end of their life, they become a ticking environmental time bomb. Discarded haphazardly, they leak toxic lead into soil and water, poisoning communities and degrading ecosystems. For years, this crisis has begged for a solution—one that balances economic needs with environmental responsibility. Enter San Lan Tech, a global leader in recycling equipment, whose lead refinery furnace and integrated recycling systems are transforming Nigeria's approach to handling scrap batteries.
The Stakes: Why Lead Acid Battery Recycling Matters in Nigeria
Nigeria is Africa's largest economy, and with growth comes a surge in vehicle ownership and industrial activity. According to the Nigerian Automotive Manufacturers Association, over 1.2 million vehicles are registered annually, each relying on lead acid batteries. When these batteries die, an estimated 150,000 metric tons of scrap batteries are generated yearly—most of which end up in informal dumps or are crushed in unregulated workshops. The consequences are dire: lead concentrations in soil near dumpsites have been found to exceed WHO safety limits by 300%, and children living nearby often suffer from lead poisoning, leading to developmental delays and chronic health issues.
The need for sustainable recycling is clear. Not only does proper recycling prevent pollution, but it also recovers valuable lead—a finite resource that Nigeria imports at great cost. "We were spending millions on imported lead for new batteries, while letting our own scrap batteries poison our land," says Dr. Amara Okafor, an environmental scientist at the University of Ibadan. "It was a cycle of waste and dependency. What we needed was a way to turn trash into treasure, right here in Nigeria."
This is where San Lan Tech stepped in. With decades of experience in designing recycling systems, the company recognized Nigeria's potential as a hub for circular economy practices. "We don't just sell equipment—we build ecosystems," explains Li Wei, San Lan's regional director for West Africa. "Our lead refinery furnace isn't just a machine; it's part of a chain that starts with collecting scrap batteries, breaks them down safely, removes toxins, and refines lead to meet industrial standards. It's about creating a closed loop that benefits both businesses and the planet."
Inside the Machine: How San Lan's Lead Refinery Furnace Works
At the heart of San Lan's solution is the lead refinery furnace—a marvel of engineering designed to turn scrap battery paste into high-purity lead. But to understand its role, we need to walk through the entire recycling process, step by step.
It all starts with collection. Scrap batteries are gathered from workshops, garages, and households, then transported to a recycling plant equipped with San Lan's lead acid battery breaking and separating plant. Here, the batteries are fed into a lead acid battery cutter—a hydraulic machine that slices through casings without releasing toxic fumes. The broken batteries are then sorted: plastic casings, lead plates, and sulfuric acid paste are separated. The paste, rich in lead oxide, is what eventually makes its way to the refinery furnace.
Before the paste reaches the furnace, it undergoes a critical step: desulfurization. San Lan's desulfurization unit treats the paste to remove sulfur compounds, which can corrode equipment and reduce lead quality. "Sulfur is the enemy of pure lead," Li Wei notes. "Our desulfurization unit uses a chemical process to bind with sulfur, turning it into a harmless byproduct that can be sold as fertilizer. It's a win-win—cleaner lead and an additional revenue stream for our clients."
Now, the treated paste is ready for the lead refinery furnace. Unlike traditional blast furnaces, which are energy-inefficient and emit heavy pollutants, San Lan's furnace uses medium frequency induction technology. This means it heats the paste using electromagnetic fields, reducing energy consumption by up to 40% compared to older models. As the paste melts, impurities rise to the surface as slag, which is skimmed off. What's left is 99.97% pure lead—good enough to be used in new batteries, construction materials, or even radiation shielding.
| Feature | San Lan Lead Refinery Furnace | Traditional Blast Furnace |
|---|---|---|
| Energy Efficiency | 40% lower energy consumption via medium frequency induction | High coal usage, low thermal efficiency |
| Lead Purity | 99.97% pure lead output | Typically 95-98% pure, requiring additional refining |
| Emission Control | Integrated with air pollution control system to capture 99% of particulates | High emissions of lead dust and SO2, often non-compliant with regulations |
| Capacity | Scalable: 500kg/hour to 5,000kg/hour | Fixed capacity, hard to adjust for demand |
| Maintenance | Modular design, easy part replacement, remote monitoring | Frequent breakdowns, high labor costs for repairs |
Breathing Clean: Air Pollution Control System in Action
For any recycling plant, emissions are the Achilles' heel. Even the most efficient furnace can release lead dust and toxic gases if not properly controlled. San Lan's answer is its air pollution control system—a suite of equipment designed to capture, filter, and neutralize pollutants before they escape into the atmosphere.
"In Nigeria, regulatory standards are tightening," says Okafor. "NESREA (National Environmental Standards and Regulations Enforcement Agency) now requires all recycling plants to meet strict emission limits. San Lan's air pollution control machines equipment are a game-changer here." The system includes electrostatic precipitators that trap 99% of lead particulates, scrubbers to remove sulfur dioxide, and activated carbon filters for volatile organic compounds (VOCs). In one project in Kano, a client reported emissions dropping from 25mg/m³ to just 0.5mg/m³ after installing San Lan's system—well below NESREA's 2mg/m³ limit.
But San Lan doesn't stop at air quality. The lead acid battery recycling process also generates wastewater, contaminated with lead and sulfur. To address this, the company integrates water process equipment, including filter press equipment, which separates solids from liquids. "The filter press is like a giant sieve," Li Wei explains. "It squeezes the water out of the battery paste, leaving a dry cake that goes to the furnace, and clean water that's recycled back into the plant. Nothing goes to waste."
From Blueprint to Reality: A Lagos Case Study
ABC Recycling Ltd.: Turning Losses into Profits with San Lan's System
In 2022, ABC Recycling, a family-owned business in Lagos, was struggling. For years, they'd operated a small-scale battery recycling workshop using manual labor and a second-hand blast furnace. "We were losing money hand over fist," recalls owner Chinedu Okonkwo. "Our furnace was so inefficient, we only recovered 60% of the lead from each battery. The rest was lost to slag or emitted as smoke. And with NESREA cracking down on polluters, we were facing fines that could shut us down."
Desperate for a solution, Okonkwo reached out to San Lan Tech. After a site visit, San Lan proposed a complete overhaul: a lead acid battery breaking and separating plant, a desulfurization unit, a medium frequency induction furnace, and an air pollution control system. The price tag was steep—$450,000—but Okonkwo saw the potential. "It was an investment, not an expense," he says. "San Lan offered a payment plan and training for my staff, which made it manageable."
The results were transformative. Within six months, ABC Recycling's lead recovery rate jumped to 92%, and their lead purity improved from 95% to 99.95%. "We went from selling low-grade lead at $1.20 per kg to high-purity lead at $2.10 per kg," Okonkwo says. "Our monthly revenue tripled. And best of all, we're no longer the neighborhood pariah. The air is cleaner, and the community has stopped complaining about our smoke."
Perhaps the biggest surprise? The air pollution control system paid for itself in a year. "We used to get complaints from the local government every week," Okonkwo laughs. "Now, NESREA uses us as a model for other recyclers. They even featured us in a documentary!"
Beyond the Furnace: San Lan's Commitment to Local Empowerment
San Lan Tech's impact in Nigeria goes beyond equipment sales. The company has invested in training programs, partnering with technical schools in Lagos and Abuja to teach young engineers how to operate and maintain recycling systems. "A machine is only as good as the people running it," Li Wei emphasizes. "We don't just install a lead refinery furnace and leave. We train a team of local technicians, so when a part needs fixing or the system needs tuning, they can handle it themselves."
This focus on local capacity-building has earned San Lan a reputation as a trusted partner. "They don't treat us like a 'developing market'—they treat us like equals," says Dr. Okafor. "When we had issues with our desulfurization unit during the rainy season, San Lan sent a technician from China within 48 hours. That level of support is unheard of here."
The company is also exploring new frontiers, including lithium battery recycling equipment, as Nigeria's tech sector grows and electric vehicles gain popularity. "Lead acid batteries will be around for decades, but lithium is the future," Li Wei notes. "Our li-ion battery breaking and separating equipment is already being tested in Abuja, and we're working on a lithium ore extraction plant to support local mining. The goal is to make Nigeria self-sufficient in battery materials—no more importing lead or lithium."
The Road Ahead: Building a Circular Economy in Nigeria
As Nigeria marches toward a more sustainable future, San Lan Tech's role continues to expand. The company is currently in talks with the federal government to build a national recycling hub in Port Harcourt, which would process 5,000 metric tons of lead acid batteries annually. "Imagine a facility where every scrap battery in the country is recycled, and the lead is used to make new batteries for Nigerian cars," Li Wei says, eyes lighting up. "That's the vision—turning Nigeria from a consumer of resources into a producer."
For Dr. Okafor, this vision can't come soon enough. "We've spent too long sacrificing our environment for short-term gains," she says. "San Lan's lead refinery furnace isn't just about recycling batteries. It's about proving that sustainability and profitability can go hand in hand. In Nigeria, we're not just cleaning up our act—we're building a model for the rest of Africa."
As the sun sets over Lagos, the hum of San Lan's lead refinery furnace at ABC Recycling echoes through the neighborhood. Where there was once smoke and despair, there's now the steady rhythm of progress—a reminder that with the right tools and vision, even the dirtiest waste can be turned into something valuable. For Nigeria, and for the planet, that's a future worth investing in.
