Solutions in control systems
The lead-acid battery recycling industry requires precise and safe control across multiple critical processes. Many facilities face challenges such as:
* Lack of system integration across process areas
* Operational inefficiencies due to manual control or outdated systems
* Safety risks caused by insufficient monitoring of operation conditions
* Non-compliance with environmental regulations
These challenges not only affect productivity but also increase operational risk and energy consumption.
With over 20 years of experience SIOS has designed and implemented integrated control systems tailored for the lead-acid battery recycling industry. Our solutions cover the following process areas:
* Battery Breakers
* Electrolyte Treatment Plants
* Rotary Furnaces
* Refining Kettles
* Dust Collectors
* Combustion Systems (Valve Trains and Burners)
We have developed project for Battery Recycling companies in, Mexico, Chile, Brazil, Philippines, China, USA, Australia, Puerto Rico, Dominican Republic, South Africa, Peru, and Venezuela.
Advantages of SIOS Control Systems
By implementing SIOS’s integrated control systems, battery recycling operations benefit from:
* Maximum efficiency through automation and precise control
* Reduced downtime via smart diagnostics and alarms
* Increased safety with protection systems at every stage
* Faster startup and commissioning
* Reduced fuel and energy consumption
* Scalable, distributed architecture compatible with existing SCADA systems
Our control solutions integrate hardware, software, and automation logic to ensure each subsystem operates safely, efficiently, and in coordination with the rest of the process. Below are specific solutions for each process stage:
Battery Breaker
Ensures the precise control of the crushing stage, where battery components (lead oxide, sulfates, plastic, etc.) are separated to reuse.
Key features:
- Precision in the Speed Control of mechanical equipment
- Engine Start/Stop Sequences and Operation Locks
- Shredder protection by battery overcharging
- Local and Remote Power Control System
- Basic Production Report
- Soft start of the crusher motor
- Detailed Monitoring of the Operation System for Operation Personnel
Rotary Furnaces
Manages the smelting process of recovered lead oxide and metal. Controls rotation, flame intensity, and combustion safety.
Key Features
- Flame Fault Protection
- Control of the Speed and Direction of the rotation of the furnace
- Furnace Combustion Control
- Use of combinations of Air and Oxygen as oxidizers
- Burner Cooling System
- Burner positioning
- Furnace Rotation and Brake
- Control Operation from the Main Board and Operation Button
- Detailed Process Monitoring
- Protection and Alarm Diagnostic System
- Easy Integration to Centralized SCADA System
- Integration with the Dust Collector System
- Ready for integration with our IS3 Infrared Armor Temperature Scanner
SIOS provides Combustion Systems for Rotary Furnaces having as central components a Valve Train and Burner. Our systems are sized to deliver the required amount of BTU’s at different times of the process. The most commonly used main fuel is Natural Gas but depending on the customer and its process other fuels have been used such as the oil.
Key Features
- Stainless Steel burner with cooling jacket and ignition pilot
- Use of combinations of Air and Oxygen as oxidizers
- Intelligent Valve Train for precise control of fuel and oxidizing flows
- Accurate measurement of fuel and fuel flow
- Safety and Flame Failure Protection
- Configuration by HMI of Fuel and Oxidizer ratio tables for 4 types of flames
- Pneumatic safety board for burner
Combustion systems use the most new technology components to provide you with years of trouble-free operation and the following benefits:
- Safety and Flame Failure Protection
- Prevents the risks of mechanical damage to the burner
- Supports Furnace Performance Optimization
- Reduction of production costs using Enriched Air technology
- Recent technology
- Fast system commissioning and start-up
Dust Collector
P: The Control system for the Dust Collector regulates the extraction of the gases generated in the Lead Smelting Furnace by passing them through a filtering system. Also, the cleaning of the modules that make up the filter system is automated and the temperature is regulated. The emissions generated are monitored to comply with current regulations.
Key Features
- Emissions Monitoring
- Different modes of operation for cleaning cycles
- Differential Pression Monitoring to determine if filters are dirty
- Protection for high temperature filter sleeves
- Remote Control and Local Extraction
- Cold Air Damper Control
- Detailed Process Monitoring
- Protection and Alarm Diagnostic System
- Easy Integration to Centralized SCADA System
- Integration with the Furnace Control System
Refining Board
P: The Lead refining process begins by entering the refining crucibles of the liquid lead recovered in the smelter. There it will remain until the alloys required by the client are achieved, and finally it is pumped into the ingot until it solidifies.
Key Features
- Panel that integrates control and independent force for each crucible.
- Single temperature controller with universal input
- Ignition and burner operation
- Flame failure protection in burner
- Lead Agitator Control
- Lead Drum Speed Control
- Quick connector for Agitator and Lead Pump
- Process Time monitoring via digital timer
- Easy integration with SCADA systems via Ethernet connection