User Reviews: Lead Paste Desulfurization Systems in Real-World Applications

Mike Thompson has run Thompson Scrap & Recycling in rural Ohio for over 15 years. "We started small—just a few trucks, a basic shredder, and a dream to keep batteries out of landfills," he says. But by 2020, the EPA came knocking. "Our lead recovery was messy, and sulfur emissions from our old furnace were through the roof. We got hit with fines and a warning: upgrade or shut down."

Thompson's team began researching lead acid battery recycling equipment, focusing on desulfurization. "We couldn't afford a full-scale plant, so we needed something compact but effective. After talking to three suppliers, we settled on a mid-sized lead paste desulfurization unit paired with a filter press. The supplier walked us through how it integrates with our existing rotary furnace for paste reduction—something we were worried about, since our furnace was older."

The first month was a learning curve. "The system uses a chemical process to strip sulfur from the paste, turning it into gypsum, which the filter press then separates," Thompson explains. "Our crew had to adjust to monitoring pH levels and slurry flow, but the supplier's tech support was on call 24/7. By month two, we noticed a difference: the paste going into the rotary furnace was lighter, less clumpy, and the furnace ran hotter without as much slag buildup."

Three years later, Thompson's system is still going strong. "We've had to ｒｅｐｌａｃｅ a few pumps, but that's normal wear and tear. The supplier sends parts within 48 hours, and we do annual maintenance ourselves. For small yards like ours, this system wasn't just an upgrade—it was a lifeline."

GreenCycle Industries in California processes over 5,000 lead acid batteries daily—a volume that demands precision and speed. "In 2021, we were hitting a bottleneck," says Maria Gonzalez, GreenCycle's Operations Manager. "Our rotary furnace for paste reduction was maxed out; we could only process 30 tons of paste per day, and the sulfur content was causing frequent shutdowns for cleaning. We needed a desulfurization system that could keep up with our high throughput."

GreenCycle invested in a high-capacity lead paste desulfurization system designed for continuous operation. "We went with a fully automated setup that integrates with our battery breaking line, paste collection, and rotary furnace. The system uses a counter-current reactor to mix paste with sodium carbonate, and the slurry is then sent to a filter press for solid-liquid separation. The whole process is controlled via a touchscreen, so our operators can adjust settings on the fly."

The results were immediate. "Within the first week, furnace downtime dropped by 60%," Gonzalez reports. "The desulfurized paste flows smoother, so the furnace can run at a consistent 25 tons per hour instead of sputtering between 18-22. We're now processing 42 tons of paste daily—40% more than before. And because the paste is lower in sulfur, our air pollution control system doesn't have to work as hard. We've cut natural gas usage by 15% since the furnace isn't burning extra fuel to combat sulfur buildup."

But it wasn't all smooth sailing. "We underestimated how much gypsum we'd produce—about 2 tons per day! We had to add a second filter press to keep up. The supplier helped us retrofit our plastic pneumatic conveying system to move the gypsum to a storage silo, which solved the problem. Now, we sell the gypsum to agricultural companies as a soil amendment. It's a small revenue stream, but it adds up."

EcoSolutions, a Texas-based environmental consulting firm, advises recycling facilities on compliance and process optimization. "We've worked with over 100 lead acid battery recyclers, from mom-and-pop yards to industrial plants," says Dr. Raj Patel, Senior Environmental Engineer at EcoSolutions. "The one upgrade we push hardest is lead paste desulfurization. It's not just about emissions—it's about profitability and longevity."

Dr. Patel recalls a 2022 project with a municipal recycling program in Dallas. "They had a new rotary furnace but skipped desulfurization to save costs. Within six months, their air pollution control system was failing EPA tests, and lead recovery was so low, they couldn't cover operational costs. We convinced them to add a desulfurization unit, and within 90 days, their sulfur dioxide emissions dropped by 92%, and lead recovery jumped from 78% to 91%."

Another client, a mid-sized recycler in Houston, was struggling with equipment lifespan. "Their rotary furnace lining was wearing out every 18 months due to sulfur corrosion," Dr. Patel explains. "After installing desulfurization, the lining lasted 36 months—doubling its lifespan. The savings on furnace repairs alone paid for the desulfurization system."

Dr. Patel notes that not all systems are created equal. "We evaluate clients' needs first: throughput, space, budget. A small yard might need a batch system with manual controls, while a plant processing 100 tons/day needs continuous automation. We also check compatibility with their filter press and air pollution control system. A desulfurization unit that produces a thick slurry won't work with a small filter press—it'll clog and slow everything down."

The City of Portland, Oregon, launched its lead acid battery recycling program in 2019 to reduce landfill waste and protect local waterways. "We wanted to set an example for sustainable public services," says Sarah Lopez, Program Director. "But our early days were rocky. Neighbors complained about odors from our facility, and initial lead recovery rates were too low to justify the cost."

Lopez's team turned to desulfurization after a community meeting. "Residents were worried about air quality, so we prioritized systems that worked seamlessly with our air pollution control equipment. We chose a compact desulfurization unit with built-in emissions monitoring—something we could show the community during tours."

The impact was immediate. "The sulfur smell? Gone. Our air pollution control system now captures over 99% of sulfur dioxide, and we post real-time emissions data on our website. Neighbors stopped complaining; in fact, we now get requests for tours from local schools!" Lopez laughs. "Operationally, the system was a game-changer. Our rotary furnace runs quieter, and the filter press produces dry, odorless gypsum that we donate to community gardens. The lead we recover is sold to a local foundry that makes bike parts—closing the loop locally."

Budget was a concern for the public program, but Lopez says the investment paid off. "We used ｇｒａｎｔ money for the initial purchase, but the savings from reduced fuel costs and higher lead sales now cover maintenance. Plus, we're diverting over 5,000 batteries from landfills yearly—something the community is proud of."