Systems and methods for selectively separating and separately processing portions of lead-acid batteries

A method for selectively breaking and separately processing portions of a lead-acid battery, comprising:

• determining, using a battery imaging system, a break point that divides top lead from a remainder of the lead content of the lead-acid battery;
• and
• breaking the lead-acid battery at the determined break point using a battery breaking device;
• and
• separating the lead-acid battery into a first portion, which includes the top lead, and a second portion, which includes the remainder of the lead content of the lead-acid battery.

A lead-acid battery processing system, comprising:

• a controller comprising a memory and a processor configured to execute instructions stored in the memory to control operation of the lead-acid battery processing system;
• an imaging system that images a lead-acid battery and provides the processor with image data, wherein the processor analyzes the image data to determine a break point that divides top lead of the lead-acid battery from a remainder of the lead content of the lead-acid battery;
• a battery breaking device that breaks the lead-acid battery at the break point based on control signals provided by the processor of the control system and separates the lead-acid battery into a first portion, which includes the top lead, from a second portion, which includes the remainder of the lead content of the lead-acid battery;
• a remelting device that receives and remelts the top lead from the first portion based on control signals provided by the processor of the controller, wherein the remelt yields a lead alloy that has similar alloying metal composition as the top lead and is suitable for use in new lead-acid batteries;
• and
• a pyrometallurgical or hydrometallurgical lead recovery system that receives and converts the remainder of the lead content of lead acid battery to metallic lead, lead oxide, or a combination thereof, suitable for use in new lead-acid batteries.