Abstract: A process for recovery of substantially all the sulfur in a spent lead-acid battery as Na2SO4 is disclosed. The process comprises (a) breaking the batteries to remove the acid, (b) separating the plastic from the lead bearing materials, (c) smelting the lead bearing materials in a reverberatory furnace in an oxidizing atmosphere to volatilize most of the sulfur in the feed as SO2, (d) scrubbing the SO2 from the off gas stream using a soluble alkaline material such as NaOH, Na2CO3, or KOH to produce a soluble sulfite solution, (e) oxidizing the sulfite solution to sulfate, preferably by turbulent mixing of the solution with air, (f) adjusting the pH by adding the sulfuric acid separated from the batteries, (g) removing the contained heavy metals, (h) crystallizing the sulfate as Na2SO4 or K2SO4, (i) separating a bleed stream from the crystallizer and removing the contained chlorides as a mixed sulfate-chloride product by evaporation of the bleed stream in another crystallizer.

Abstract: An electrowinning anode is formed by tightly joining a sheet of lead anode material to a copper busbar using solder to fill the joint. The busbar is optimally coated with a tin alloy by dipping the busbar into the alloy prior to being joined with the sheet. A lead coating is electrodeposited onto the busbar and the soldered joint to provide a complete metallurgical seal and good resistance to acid corrosion.

Abstract: Calcium and aluminum are alloyed into lead by adding a eutectic calcium-aluminum alloy to molten lead preferably at a temperature of at least 1020.degree.. The eutectic alloy contains about 73% calcium and about 27% aluminum.

Abstract: Low antimony lead alloys suitable for use as grid material in maintenance-free high capacity lead acid batteries are disclosed. The alloys comprise 0.6 to 1.1 weight percent antimony, 0.06 to 0.25 weight percent arsenic, 0.1 to 0.4 weight percent tin, 0.06 to 0.11 weight percent copper, and the balance lead. A preferred alloy contains 0.8 weight percent antimony, 0.15 weight percent arsenic, 0.25 weight percent tin and 0.08 weight percent copper.

Abstract: A lead anode for electrowinning metals from sulfuric acid solutions is formed by soldering a sheet of lead anode material endwise in a slot, which extends longitudinally along and partially through a lead alloy coated copper bus bar and into which the sheet fits tightly, and thereafter depositing lead alloy filler at all joints between the bar and anode. Anodes thus constructed have a uniform, smooth joint between the bar and sheet and thus are corrosion resistant and exhibit uniform conductivity.

Abstract: An improved insoluble anode for electrowinning is described which comprises a graphite substrate covered by a tight fitting sheet of a nonconductive electrolytically inert mesh material over which covered substrate is electrodeposited a layer of lead dioxide. The anode is formed by covering the graphite substrate with a sheet of the inert mesh material and thereafter electrodepositing lead dioxide thereon until a smooth layer of lead dioxide completely covers the mesh material. The anodes are electrolytically stable and are not susceptible to cracking.

Abstract: An electrolyte and a process for reducing lead peroxide formation when electrowinning lead from inorganic acid solutions are disclosed. In accordance with the invention, arsenic is added to an inorganic acid electrolyte containing lead, whereby oxygen is evolved at the anode while lead peroxide formation is reduced or eliminated during electrolysis.

Abstract: A process for recovery of substantially all lead values in battery sludge as metallic lead is disclosed. By means of the process, lead is substantially completely and efficiently recovered as metallic lead in an environmentally acceptable manner. The process comprises (a) subjecting the sludge to low temperature reducing conditions; (b) converting lead sulfates to insoluble nonsulfur containing compounds while solubilizing all sulfur materials and thereafter separating the solid residue by solid-liquid separation techniques; (c) dissolving the solid products resulting from steps (a) and (b) in an acid selected from the group consisting of fluoboric and fluosilicic acid; (d) collecting the supernatant from step (c) by means of solid-liquid separation techniques; and (e) electrowinning the lead from the collected supernatant. The lead peroxide reduction of step (a) may be effected by low temperature reducing roasts or by contacting the lead peroxide with sulfur dioxide gas or sulfites.