Design of a Reactor for Hydrometallurgical Recycling of Lead

This article details the design and operation of a 500 L stirred hydrometallurgical reactor for sustainable lead recycling from used lead–acid batteries. Mechanical design followed ASME Section VIII and API 650 standards, supported by finite element analysis and simulation conducted in SolidWorks. Sodium citrate was selected as the leaching reagent due to its effectiveness and comparatively low environmental impact. The agitation system, operated at 400 rpm with axial impellers and vertical baffles, demonstrated high mass transfer efficiency, achieving recoveries above 90%. Critical structural parameters were dynamically assessed, and solutions were proposed to reduce vibration and wear. This technology is presented as an eco-friendly alternative to traditional casting processes, with the potential to reduce occupational hazards and toxic emissions while promoting more sustainable recycling practices within the industry. Smart citations: https://scite.ai/reports/10.61467/2007.1558.2026.v17i1.1165Dimensions.Open Alex.