An integrated two-step
process, comprising vacuum chlorinating
and hydrothermal synthesis, is developed for direct recovery of the
three-dimensional lead sulfide (PbS) dendrite product from the lead
paste of spent lead-acid batteries (LABs). In the vacuum chlorinating
stage, different lead components, comprising lead (Pb), lead oxide
(PbO), lead dioxide (PbO2), and lead sulfate (PbSO4) in the spent lead paste, are all converted into volatile
lead chloride (PbCl2) with calcium chloride (CaCl2) as the environmentally friendly reagent. Sulfur is synchronously
fixed into chlorinated residues in the form of calcium sulfate. Response
surface methodology shows that the optimal conditions are a temperature
of 630 °C, time of 34.0 min, and Cl:Pb molar ratio of 64:1 to
achieve a maximum PbCl2 recovery percentage of 98.37 wt
%. CaCl2 in the solid residues is regenerated by a dissolution–filtration–evaporation
process. In the hydrothermal synthesis stage, high-purity PbCl2 is successfully converted into PbS with dendritic morphology
by using thiourea as the sulfur source at 120 °C for 24 h. The
possible growth mechanism is investigated, and it is confirmed that
the crystal growth of lead sulfide dendrites can be attributed to
the tendency of growth to be in the ⟨100⟩ direction.
The proposed process is feasible for recovery of high-value functional
material product (PbS) from spent LABs instead of the conventional
metallic lead product.