Technical Manuals for Lead Paste Desulfurization System Installation

Lead acid batteries power our daily lives—from the cars we drive to the backup systems that keep hospitals and data centers running. But when these batteries reach the end of their life, they don't just become waste; they become a valuable resource. That's where lead acid battery recycling equipment steps in, turning scrap batteries into reusable lead, plastic, and other materials. At the heart of this process lies the lead paste desulfurization system—a critical component that transforms lead sulfate, a key byproduct of spent batteries, into pure lead compounds ready for refining.

Installing a de-sulfurization machines equipment isn't just about placing a machine in a room. It's about creating a seamless link in the recycling chain, ensuring efficiency, safety, and compliance with strict environmental standards. A well-installed system minimizes downtime, maximizes reagent efficiency, and reduces the risk of leaks or contamination. Whether you're setting up a new recycling plant or upgrading an existing line, this manual will guide you through every step—from unboxing the equipment to integrating it with your filter press equipment, air pollution control system, and other key components. Let's get started.

Site Assessment: Setting the Stage for Success

Before you even unpack the system, take time to evaluate your installation site. The desulfurization system needs space—not just for the main unit, but for auxiliary components like reagent tanks, pumps, and piping. Aim for a minimum clearance of 1.5 meters around the unit to allow for maintenance and safe operation. Check that the floor can support the system's weight (refer to the technical specifications sheet for exact figures)—concrete foundations are ideal, as they prevent shifting over time.

Next, verify utilities: the system requires a stable power supply (typically 380V/50Hz, three-phase), clean water for reagent preparation, and drainage for wastewater (which will later connect to your effluent treatment machine equipment). Ventilation is also key—ensure the area has adequate airflow to disperse any fumes, though the system will later integrate with your air pollution control system equipment for full compliance.

Safety First: Protecting Your Team

Desulfurization involves handling corrosive reagents (like sodium carbonate or caustic soda) and electrical components. Before starting, confirm all installers have completed safety training, including how to use personal protective equipment (PPE): chemical-resistant gloves, goggles, aprons, and steel-toed boots. Post emergency contact numbers (local poison control, fire department, and your equipment supplier) near the installation area. Also, ensure fire extinguishers (Class B for chemical fires) and an eyewash station are within 10 meters of the work zone.

Tools & Materials: What You'll Need

Having the right tools on hand avoids delays. Below is a checklist of essential items:

Unboxing & Inspection: Checking for Damage

When the equipment arrives, inspect the packaging for signs of rough handling—dents, tears, or water damage. Use a forklift or pallet jack to move the crate to the installation site (never drag it, as this can bend frame components). Carefully remove the packaging (use a utility knife, taking care not to cut into the equipment) and lay out all parts on a clean, dry tarp. Compare the delivered parts to the packing list included in your shipment—common components include the reactor vessel, agitator motor, reagent dosing pumps, control panel, and connecting brackets. If any parts are missing or damaged, contact your supplier immediately—do not proceed with installation until replacements arrive.

1. Foundation Setup: A Solid Base

The desulfurization system's performance depends on a level, stable foundation. Start by marking the anchor bolt positions on the concrete floor using the template provided in your installation kit. Drill holes to the specified depth (typically 150mm) and diameter (M16 or M20 bolts, depending on unit size). Clean debris from the holes with compressed air, then ｉｎｓｅｒｔ anchor bolts and tighten the nuts to secure them in place (leave 5-10mm of thread exposed for attaching the unit's base plate).

Place a spirit level across the foundation area to check for unevenness. If the floor slopes more than 0.5mm per meter, use a cementitious leveling compound to create a flat surface. Allow the compound to cure fully (24-48 hours) before proceeding—rushing this step can lead to misalignment and leaks later.

2. Main Unit Placement: Aligning for Precision

With the foundation ready, use a crane or hydraulic lift to position the main reactor unit over the anchor bolts. Lower it slowly, guiding the base plate holes onto the bolts. Once seated, place the spirit level on top of the reactor vessel and check both front-to-back and side-to-side levels. Adjust using stainless steel shims under the base plate until the bubble is centered. Tighten the anchor nuts gradually (in a crisscross pattern) to 50% torque, then repeat to full torque (refer to the technical specs for exact values—over-tightening can warp the base plate).

3. Connecting Auxiliary Components

Now it's time to link the system's "organs": reagent tanks, pumps, and agitators. Start with the reagent dosing system: connect the PVC piping from the sodium carbonate tank to the reactor's inlet port using PTFE thread seal tape. Hand-tighten first, then use an adjustable wrench to give a ¼-turn—over-tightening can crack plastic fittings. Next, mount the agitator motor to the reactor lid, ensuring the shaft aligns with the impeller (misalignment causes vibration and premature bearing failure). Secure the motor with the provided bolts, then connect the electrical wiring to the control panel (follow the wiring diagram in your manual—color-coded wires simplify this step).

Finally, attach the slurry outlet hose to the reactor's bottom port. This hose will later feed into your filter press equipment, so leave enough slack (but not too much—excess hose can kink and restrict flow). Use hose clamps to secure the connection, and label the hose "Desulfurized Slurry Out" to avoid confusion during later integration.

4. Integrating with Filter Press Equipment

The filter press is where the magic of separation happens: after desulfurization, the slurry (a mix of lead compounds and liquid) flows into the filter press, which squeezes out moisture to leave dry cake ready for lead refinery. To connect them, align the slurry outlet hose with the filter press inlet valve. Use aｕｎｉｏｎfitting to join the two (this allows for easy disconnection during maintenance). Check that the hose slope is at least 1:100 to ensure gravity-assisted flow—if the filter press is lower than the reactor, you may need a transfer pump (consult your supplier if unsure).

Connecting to Lead Acid Battery Breaking & Separation System

Your desulfurization system doesn't work alone—it's part of a larger lead acid battery recycling line. Upstream, the lead acid battery breaking and separation system crushes spent batteries, separating lead grids, plastic casings, and lead paste. The paste (which contains lead sulfate) is conveyed to your desulfurization system via a screw conveyor or pneumatic line. To integrate, connect the conveyor's outlet to the reactor's paste inlet hopper. Adjust the conveyor speed to match the reactor's processing capacity (typically 500-2000kg/hour, depending on your system model) to avoid overloading.

Air Pollution Control: Keeping Fumes in Check

Desulfurization reactions can release small amounts of carbon dioxide and sulfur dioxide fumes. To capture these, connect the reactor's vent port to your air pollution control system equipment (e.g., a scrubber or baghouse). Use galvanized steel ducting for this connection, ensuring a tight seal with gasketed flanges. The duct should slope slightly downward toward the pollution control system to prevent condensation buildup, which can corrode metal over time. Test the airflow with a manometer—aim for a velocity of 10-15 m/s to ensure fumes are pulled away from the work area.

Effluent Treatment: Managing Wastewater

During desulfurization, wastewater is generated from reagent mixing and slurry washing. This water contains trace chemicals and must be treated before disposal. Connect the reactor's drain valve to your effluent treatment machine equipment using PVC piping. Install a flow meter in this line to monitor water usage and ensure the treatment system isn't overloaded. Add a Y-strainer before the treatment inlet to catch any solid particles that could clog filters—clean the strainer weekly during initial operation to prevent buildup.

Control Panel Programming: The Brain of the System

Your system's control panel coordinates all operations—agitator speed, reagent dosing, and interlocks with upstream/downstream equipment. Power up the panel (ensure the main switch is off before connecting the electrical supply), then follow the programming guide to set parameters: reaction time (typically 60-90 minutes), pH setpoint (9-10 for optimal desulfurization), and agitator RPM (200-300, depending on slurry viscosity). Program interlocks so the system shuts down if the filter press is full or the air pollution control system equipment stops working—this prevents unsafe conditions.

Leak Testing: Catching Issues Early

Before introducing reagents, test for leaks in the piping and connections. Close all valves, then fill the reactor with water (up to 50% capacity). Open the outlet valve to let water flow through the system into the filter press equipment. Inspect all joints, hoses, and fittings for drips—tighten connections or ｒｅｐｌａｃｅ gaskets as needed. Let the system hold pressure for 30 minutes; if the water level in the reactor drops more than 1%, there's a leak (check the drain valve first—it's a common culprit).

Dry Run: Testing Motors & Sensors

With leaks fixed, perform a dry run (no water or reagents). Power on the control panel and start the agitator—listen for unusual noises (grinding or squealing may indicate misalignment). Check that the reagent pumps activate when the "Start" button is pressed, and that the conveyor from the breaking system feeds paste into the hopper (use a small amount of inert material like sand to simulate paste flow). Verify that sensors (pH, temperature, level) display accurate readings—if a pH sensor shows "err," calibrate it using buffer solutions (pH 7 and pH 10) as per the manual.

Wet Test with Reagents: Simulating Real Conditions

Now it's time for the real test: a small-batch run with actual reagents. Prepare a sodium carbonate solution (10% concentration) in the reagent tank, then load 50kg of lead paste into the reactor (use paste from your breaking system for authenticity). Start the agitator, begin dosing reagent, and monitor the pH—within 15 minutes, it should stabilize between 9 and 10. Let the reaction run for 60 minutes, then transfer the slurry to the filter press equipment. After pressing, inspect the dry cake: it should be crumbly, with a lead sulfate content below 5% (test using a XRF analyzer if available). If the cake is too wet or sulfur levels are high, adjust the reagent dosage or reaction time and repeat the test.

Safety System Checks: Preparing for Emergencies

Finally, test the safety systems. Trip the emergency stop button on the control panel—all motors should shut down within 2 seconds, and the main power indicator should flash red. Simulate a high-temperature alarm by placing a heat gun near the reactor's temperature sensor; the system should sound an alarm and stop reagent dosing. Reset the alarms and confirm they clear before proceeding to full production.

Daily Checks: Quick Inspections

Spend 10 minutes each shift checking:

• Reagent tank levels—refill sodium carbonate solution if below 20%.
• Filter press cake discharge—ensure it's consistent (no clogs in the press plates).
• Hoses and piping for bulges or cracks—ｒｅｐｌａｃｅ immediately if found.
• Control panel displays—no error codes or flashing alarms.

Weekly Tasks: Preventive Care

Set aside 1 hour weekly for deeper checks:

• Clean pH and temperature sensors with a soft brush and distilled water—mineral deposits can skew readings.
• Lubricate agitator motor bearings with lithium grease (use the zerk fitting on the motor housing).
• Inspect reagent pump diaphragms for wear—look for cracks or fluid leaks around the pump head.

Monthly & Annual Maintenance

Every month, tighten electrical connections in the control panel (loose wires cause voltage drops and motor burnout). Inspect the reactor's inner lining for corrosion (small pits can be repaired with epoxy; large areas may require re-lining). Annually, drain and flush the reactor with a 5% citric acid solution to remove scale buildup, and ｒｅｐｌａｃｅ all gaskets and O-rings—they harden over time, even if they look intact.

Even with careful installation, issues can arise. Here's how to tackle them:

Low Desulfurization Efficiency (High Lead Sulfate in Cake)

Cause: Incorrect reagent dosage, low pH, or insufficient reaction time. Solution: Check the reagent pump flow rate (use a graduated cylinder to measure output over 1 minute). If it's below spec, clean the pump filter or ｒｅｐｌａｃｅ the impeller. Adjust the pH setpoint up by 0.5 and extend reaction time by 15 minutes, then retest.

Agitator Vibration

Cause: Misaligned impeller, worn bearings, or unbalanced load. Solution: Stop the agitator and check the impeller clearance (should be 2-3mm from the reactor bottom). Tighten the impeller nut if loose. If vibration persists, ｒｅｐｌａｃｅ the motor bearings—they typically last 20,000 hours of operation.

Air Pollution Control System Alarms

Cause: Clogged filter in the air pollution control system equipment, or fan motor failure. Solution: Open the scrubber or baghouse and inspect filters—clean or ｒｅｐｌａｃｅ them if they're caked with dust. Check the fan motor amperage; if it's drawing more than rated current, the motor may be failing (contact your supplier for replacement).

Installing a lead paste desulfurization system is a journey—one that transforms a collection of parts into a vital link in the lead acid battery recycling process. By following these steps, you've laid the groundwork for efficient, safe, and compliant operation. Remember, a well-installed system not only boosts productivity but also protects your team and the environment.

As you ramp up production, keep this manual handy, and don't hesitate to reach out to your supplier's technical support team with questions. With proper care, your de-sulfurization machines equipment will serve your recycling plant for years to come—turning waste into resources, one battery at a time.