At the beginning of the year i had a client contact me about processing a ton batteries a month. Most people try to hammer mill the batteries open but this will lead to a high iron contamination. They were pulling as much iron out as possible with several methods but it was time consuming and troublesome. It was causing problems with the recover and refining stages because of the high iron content. I used a little physic and some engineering and $ 30,000 dollars later came up with the answer. I love silver batteries ! One important part is to do a good water wash to remove as much potassium or sodium as possible before you start the refining process. Once those problems are removed ( The opening of the batteries and Base that eats the acid ) then recover is simple. Here's the first video of them starting to get the design down pat.
https://www.youtube.com/watch?v=-oF8GvEKnhg&list=UU3lLIWQksiZIClYudB5gK3Q
I ran two types of tests – first filling a tube with batteries and heating them horizontally configured coil. I ran the heat for just 1.1 seconds and about 1/3 of the batteries exploded. Leaving the heat on longer would have certainly exploded all of them as every battery was expanded and ready to go.
We then changed the coil configuration to a vertical coil where we could just dispense the batteries down through the coil. With this configuration, we made a make shift paper funnel and dropped a handful of batteries through the coil. You could see smoke coming from the end of the tube, but we only had 1-2 batteries blow.
With this test we were running with 7.5kW of power and while we did not get any batteries to blow, they did get quite hot to the touch and most, if not all the gaskets had expanded. We feel the vertical approach would be the best approach to process a high volume of batteries, however the job would require more power and a special induction coil from rectangular tubing.
We are thinking that 25kW of power would be required for this job, which has a $31,000.00 budget and to design and build the proper coil you would be looking at $2-3,000.00. We do have a 25kW system in our lab to run further tests with, if your customer has the budget for the systems and is willing to fund the building of the proper coil for continued testing.
Right now the coil length we had was about 6” in length and we think we need to be about 8-10” in length, with a more robust design to handle the additional power.
I look forward to your review and response