A closed loop electrochemical process of recovery of high-purity lead uses continuous formation of adherent lead on a cathode from an electrolyte that is used to dissolve desulfated lead paste. Preferred cathodes include aluminum containing cathodes that are operated in methane sulfonic acid to produce a micro- or nanoporous mixed matrix metallic composition and lead dioxide formation at the anode is avoided using appropriate anode configurations or operating conditions

A closed loop electrochemical process of recovery of high-purity lead uses continuous formation of adherent lead on a cathode from an electrolyte that is used to dissolve desulfated lead paste. Preferred cathodes include aluminum containing cathodes that are operated in methane sulfonic acid to produce a micro- or nanoporous mixed matrix metallic composition and lead dioxide formation at the anode is avoided using appropriate anode configurations or operating conditions

In the electrolytic refining of lead in a sulfamate bath, the production of a white residue is suppressed, and a decrease in the lead concentration in the electrolytic solution is suppressed. A method for electrolytically refining lead in a sulfamate bath, comprising performing electrolytic refining at a decomposition rate of sulfamic acid controlled at 0.06%/day or less.

In the electrolytic refining of lead in a sulfamate bath, the production of a white residue is suppressed, and a decrease in the lead concentration in the electrolytic solution is suppressed. A method for electrolytically refining lead in a sulfamate bath, comprising performing electrolytic refining at a decomposition rate of sulfamic acid controlled at 0.06%/day or less.

Disclosed are solutions for the recovery of elemental metals at industrial scales without smelting including, for example, the recovery of near-pure lead from recycled LABs via specialized electrolytic processing. Further disclosed are new processes, innovative electrolyzer designs, and/or novel utilization of supplemental chemicals necessary for successful electrolysis of pure metal from impure forms (e.g., pure lead from lead oxides), and especially applicable for solid-state electrolysis of mixtures comprising lead paste, electrolyte, and supplemental chemicals. With particular regard to recovering near-pure lead during LAB recycling, solid-state electrolysis of mixtures comprising impure lead (e.g., lead paste) is made possible and scalable to industrial levels via utilization of a vertically-arranged series of two-compartment horizontal cathodes or two-compartment horizontal bipolar cathodes in an electrolyzer assembly to simultaneously produce, for example, elemental lead (Pb), sodium hydroxide (NaOH), and chlorine gas (Cl2).

Disclosed are solutions for the recovery of elemental metals at industrial scales without smelting including, for example, the recovery of near-pure lead from recycled LABs via specialized electrolytic processing. Further disclosed are new processes, innovative electrolyzer designs, and/or novel utilization of supplemental chemicals necessary for successful electrolysis of pure metal from impure forms (e.g., pure lead from lead oxides), and especially applicable for solid-state electrolysis of mixtures comprising lead paste, electrolyte, and supplemental chemicals. With particular regard to recovering near-pure lead during LAB recycling, solid-state electrolysis of mixtures comprising impure lead (e.g., lead paste) is made possible and scalable to industrial levels via utilization of a vertically-arranged series of two-compartment horizontal cathodes or two-compartment horizontal bipolar cathodes in an electrolyzer assembly to simultaneously produce, for example, elemental lead (Pb), sodium hydroxide (NaOH), and chlorine gas (Cl2).

This invention presents an electrochemical metallurgical technique for extracting metals and sulfur from metal sulfides, offering an adjustable composition and mechanical properties during electrode preparation. The metal sulfide anode, submerged in an electrolyte with a cathode made of materials like titanium, copper, stainless steel, lead, zinc, aluminum or graphite, undergoes electrolysis. This process oxidizes sulfur in the metal sulfide to the anode and releases metal ions into the electrolyte, where they're reduced at the cathode. The method yields metal at the cathode and sulfur at the anode, with minimal environmental impact, low investment, and straightforward process.

This invention presents an electrochemical metallurgical technique for extracting metals and sulfur from metal sulfides, offering an adjustable composition and mechanical properties during electrode preparation. The metal sulfide anode, submerged in an electrolyte with a cathode made of materials like titanium, copper, stainless steel, lead, zinc, aluminum or graphite, undergoes electrolysis. This process oxidizes sulfur in the metal sulfide to the anode and releases metal ions into the electrolyte, where they're reduced at the cathode. The method yields metal at the cathode and sulfur at the anode, with minimal environmental impact, low investment, and straightforward process.

The present disclosure relates generally to recycling lead-acid batteries, and more specifically, relates to purifying and recycling the lead content from lead-acid batteries. A method includes reacting a lead-bearing material with a first carboxylate source to generate a first lead carboxylate. The method includes reacting the first lead carboxylate with a second carboxylate source to generate a second lead carboxylate. The method further includes applying an electrical bias to an aqueous solution of the second lead carboxylate to generate metallic lead.

The present disclosure relates generally to recycling lead-acid batteries, and more specifically, relates to purifying and recycling the lead content from lead-acid batteries. A method includes reacting a lead-bearing material with a first carboxylate source to generate a first lead carboxylate. The method includes reacting the first lead carboxylate with a second carboxylate source to generate a second lead carboxylate. The method further includes applying an electrical bias to an aqueous solution of the second lead carboxylate to generate metallic lead.