Novel PbO@C composite material directly derived from spent lead-acid batteries by one-step spray pyrolysis process.

[Display omitted] • Spray pyrolysis is used for lead-acid battery recycling for the first time. • Low-impurity PbO@C is prepared from the recovered lead acetate solution. • Recovered PbO@C shows better electrochemical performance than commercial PbO. • Computational fluid dynamics (CFD) is used for study of spray pyrolysis mechanisms. • The cell made from PbO@C runs 295 charging/discharging cycles (100%DOD). A one-step spray pyrolysis process is investigated for the first time in the field of spent lead-acid batteries (LABs) recycling. The spent lead paste that derived from spent LAB is desulfurized and then leached to generate the lead acetate (Pb(Ac) 2) solution, which is then sprayed directly into a tube furnace to prepare the lead oxide (PbO) product by pyrolysis. The low-impurity lead oxide product (9 mg/kg Fe and 1 mg/kg Ba) is obtained under the optimized conditions (the temperature of 700 °C, the pumping rate of 50 L/h, and the spray rate of 0.5 mL/min). The major crystalline phases of the synthesized products are identified to be α-PbO and β-PbO. In the spray pyrolysis process, Pb(Ac) 2 droplets are sequentially transformed into various intermediate products: H 2 O(g)@Pb(Ac) 2 solution, Pb(Ac) 2 crystals@PbO, and the final PbO@C product. Owning its carbon skeleton structure, the recovered PbO@C product (carbon content of 0.14%) shows better performance than the commercial ball-milled lead oxide powder in battery tests, with higher initial capacity and better cycling stability. This study could provide a strategy for the short-route recovery of spent LABs. [ABSTRACT FROM AUTHOR]