An Eco-balance of a Recycling Plant for Spent Lead–Acid Batteries

This study applies Life Cycle Assessment (LCA) methodology to present an eco-balance of a recycling plant that treats spent lead–acid batteries. The recycling plant uses pyrometallurgical treatment to obtain lead from spent batteries. The application of LCA methodology (ISO 14040 series) enabled us to assess the potential environmental impacts arising from the recycling plants operations. Thus, net emissions of greenhouse gases as well as other major environmental consequences were examined and hot spots inside the recycling plant were identified. A sensitivity analysis was also performed on certain variables to evaluate their effect on the LCA study. The LCA of a recycling plant for spent lead–acid batteries presented shows that this methodology allows all of the major environmental consequences associated with lead recycling using the pyrometallurgical process to be examined. The study highlights areas in which environmental improvements are easily achievable by a business, providing a basis for suggestions to minimize the environmental impact of its production phases, improving process and company performance in environmental terms.     

Economies of scale for future lithium-ion battery recycling infrastructure

While lithium-ion battery (LIB) technology has improved substantially to achieve better performance in a wide variety of applications, this technological progress has led to a diverse mix of batteries in use that ultimately require waste management. Development of a robust end-of-life battery infrastructure requires a better understanding of how to maximize the economic opportunity of battery recycling while mitigating the uncertainties associated with a highly variable waste stream. This paper develops and applies an optimization model to analyze the profitability of recycling facilities given current estimates of LIB technologies, commodity market prices of materials expected to be recovered, and material composition for three common battery types (differentiated on the basis of cathode chemistry). Sensitivity analysis shows that the profitability is highly dependent on the expected mix of cathode chemistries in the waste stream and the resultant variability in material mass and value. The potential values of waste streams comprised of different cathode chemistry types show a variability ranging from $860 per ton¹ for LiMn₂O₄ cathode batteries to $8900 per ton for LiCoO₂ cathode batteries. In addition, these initial results and a policy case study can also help to promote end-of-life management and relative policymaking for spent LIBs.     

Technological improvements in automotive battery recycling

Recycling of automotive batteries for the recovery of secondary lead is extremely important in Brazil, for the country does not possess large reserves of this metal. Lead is one of the most widely used metals in the world, but it is highly toxic, posing risks for humans and for the environment if not utilized or treated adequately. Industrial waste containing lead in Brazil are classified by the Brazilian Residue Code (NBR—10004:2004) as hazardous. The lead recycling process employed by the recycling industry in Brazil is the pyrometallurgical process in a rotary furnace. This process consists of four stages: (1) grinding of the battery to separate plastic, electrolyte and lead plates; (2) lead reduction in a rotary furnace; (3) separation of metallic lead from slag; and (4) refining of recycled lead. The purpose of this work is to propose process improvements aimed primarily at increasing production output by reducing the loss of lead in slag and particulates, thereby providing a healthier work environment in line with Brazilian environmental and labor laws.     

Management of used lead acid battery in China: Secondary lead industry progress,policies and problems

The amount of used lead acid batteries rises along with the rapid development of battery manufacture in China. The battery manufacture and recycling industry has developed sharply in these recent 5 years. The annual production of secondary lead from used lead acid batteries in China increased rapidly to 1.5 million tonnes (MT) in 2013, making china the world's largest secondary lead producer. Secondary lead enterprises are mainly located in the middle and eastern regions of China, with a legal production capacity of 3 MT/year. Environmental pollution problems began to happen frequently from 2009. After 2011, the government began to put in efforts to promote pollution control, eliminate outdated production capacity, support advanced production and technology innovation research, and has achieved remarkable results. However, the main existing problems are that the proportion of secondary lead production is only 30% of the total lead production, no formal recycling network has been established and the overall level of industrial technology and equipment is outdated. Compared with developed countries, this paper predicts that, secondary proportion will reach 44% in 2015 and 60% in 2028. Finally some countermeasures are given to the recycling mode and technology promotion.     

我国废铅酸蓄电池污染防治技术及政策探讨

废铅酸蓄电池回收环节产生的废渣、铅酸污泥等属于危险废物,必须按照危险废物进行管理;而废铅酸蓄电池铅回收过程也会产生二次污染,其生产过程和管理不当会产生严重的环境污染。本文在分析我国再生铅生产工艺技术现状、废铅酸蓄电池资源再生过程污染源的基础上,对废铅酸蓄电池资源再生过程污染源治理和污染预防措施以及目前废铅酸蓄电池铅回收相关政策和管理要求进行了较为系统的分析和总结。     

Life cycle inventory of recycling portable nickel–cadmium batteries

In this study, the environmental impact of recycling portable nickel–cadmium (NiCd) batteries in Sweden is evaluated. A life cycle assessment approach was used to identify life cycle activities with significant impact, the influence of different recycling rates and different time boundaries for emissions of landfilled metals. Excluding the user phase of the battery, 65% of the primary energy is used in the manufacture of batteries while 32% is used in the production of raw materials. Metal emissions from batteries to water originate (96–98%) from landfilling and incineration. The transportation distance for the collection of batteries has no significant influence on energy use and emissions. Batteries manufactured with recycled nickel and cadmium instead of virgin metals have 16% lower primary energy use. Recycled cadmium and nickel metal require 46 and 75% less primary energy, respectively, compared with extraction and refining of virgin metal. Considering an infinite time perspective, the potential metal emissions are 300–400 times greater than during the initial 100 years. From an environmental perspective, the optimum recycling rate for NiCd batteries tends to be close to 100%. It may be difficult to introduce effective incitements to increase the battery collection rate. Cadmium should be used in products that are likely to be collected at the end of their life, otherwise collection and subsequent safe storage in concentrated form seems to offer the best solution to avoid dissipative losses.     

Ecotoxicity assessment of slag generated in the process of recycling lead from waste batteries

The aim of this study was to evaluate the possible toxicity of the leachate produced by the residues generated in the process of recycling lead from waste batteries. These residues are slag, which once formed, is characterised by its content in ferrous sulphide, sodium carbonate as well as residual coke from the process. It also contains, as minor components, lead and other heavy metals. The slag was stored and watered periodically over a period of 6 months, its composition changing until finally becoming inert, with no exothermal activity. The slag was leached, and its ecotoxicity was determined by means of the bioluminescence test, along with its content in heavy metals. The results obtained indicate a greater degree of toxicity in the residues with a shorter storage period than the established one, and which were therefore still in the phase of decomposition. However, in the samples taken on completing 6 months of storage, the EC₅₀ value of the leachate was found to be higher than 3000 mg/l. Hence, a storage period under suitable environmental conditions which leads to inactivity of the residue as well as a decrease in its ecotoxicity, is considered absolutely essential. At the same time, a direct relationship was observed between the lead content and the ecotoxicity value.     

Nickel recovery/removal from industrial wastes: A review

Nickel is an important metal, heavily utilized in industry mainly due to its anticorrosion properties. As a consequence, nickel containing wastes such as spent batteries and catalysts, wastewater and bleed-off electrolytes are generated in various processes. These wastes could have a negative impact on the environment and human health if they contaminate soil, water and air. The present review addresses the environmental and economical aspects of nickel recovery/removal from various types of wastes. The main physico-chemical technologies for processing various effluents and wastewaters containing nickel are reviewed and discussed. Nickel recovery from spent batteries, catalysts, electronic waste and other sources is described. Hydrometallurgical approaches are emphasized. Recovery of nickel from wastes is important not only for economical aspects, but also for environmental protection.     

Comparison study and parameter identification of three battery models for an off-grid photovoltaic system

There is growing interest in solar batteries, especially for photovoltaic (PV) applications. Therefore, an accurate battery model is required for the PV system because of its influence on system efficiency. Several mathematical models of batteries have been described in the scientific literature. However, this paper reviews three electrochemical models most commonly used for PV systems, such as Shepherd, Manegon and Coppetti, in order to define the most appropriate model for PV systems. This paper discusses an application of the pattern search optimization technique to extract the parameters of three battery models derived from experimental test results obtained from sealed gelled lead acid batteries for both charge and discharge modes. A comparative case and regression analysis based on statistical tests and a quantitative method were conducted to demonstrate the effectiveness and accuracy of the updated model from the three aforementioned. The simulation results and tests performed on the battery charge and discharge modes lead us as well to approve the algorithm’s accuracy regarding the updated model.     

南方某市城区电池使用、回收现状分析及对策初探

电池的使用现状和污染问题日益在我国得到重视。本文以南方某市城区为例,对其电池生产、销售、使用、回收和处置各环节进行了详细的调查和研究,分析存在的主要问题,较为精确的预测了废电池产生数量及其与人口数量的关系,将国外发达国家的经验技术与我国国情相结合,提出了政府、民间组织和生产商三方合作的废电池回收模式,并针对生产、处置等环节提出了相应的污染防治建议。     

Cadmium—Towards a rational use of a toxic element

Because of its toxicity, cadmium creates an environmental problem as well as a health hazard for exposed workers. Most cadmium emissions arise from the intentional use of the element. It is therefore mandatory to reduce cadmium consumption to the lowest possible level. Cadmium pigments, mainly used in plastic processing, can be replaced in all applications where the processing temperature does not exceed 300°C. Newly developed polyvinyl chloride stabilizers promise to be an excellent substitute for cadmium stabilizers in even the most demanding applications. Cadmium plating, still extensively used in the United States and the West Germany, has been virtually abandoned in Japan. Improved lead acid batteries are replacing vented nickel cadmium batteries because of their cost effectiveness. While in these applications cadmium use is declining, more and more cadmium is needed for the manufacturing of sealed nickel cadmium batteries. These relatively small electrochemical cells are used mainly by individual consumers. Here cadmium can only be replaced in some marginal applications. The high cadmium content of these batteries (up to 22%) makes them a good candidate for recycling of the heavy metal.     

Implications for the carrying capacity of lithium reserve in China

China is a major supplier of rechargeable lithium batteries for the world's consumer electronics (CE) and electric vehicles (EV). Consequently, China's domestic lithium resources are being rapidly depleted, and the development of the CE and EV industries will be vulnerable to the carrying capacity of China's lithium reserves. Here we find that lithium demand in China will increase significantly due to the continuing growth of demand for CE and the briskly emerging market for EV, resulting in a short carrying duration of lithium, even with full recycling of end-of-life lithium products. With these applications increasing at an annual rate of 7%, the carrying duration of lithium reserves will oblige the end-of-life products recycling with a 90% rate. To sustain the lithium industry, one approach would be to develop the collection system and recycling technology of lithium-containing waste for closed-loop lithium recycling, and other future endeavors should include developing the low-lithium battery and optimizing lithium industrial structure.     

Numerical and experimental investigation of state of health of Li-ion battery

ABSTRACT

Estimation of State of Health (SoH) of Lithium-ion (Li-ion) battery is essential to predict the lifespan of batteries of an electric vehicle (EV). The efficient prediction of battery health indicates to the effective and safe operation of EV. However, delivering an effective and accurate method for the estimation of SoH in the real condition is truly a challenging task. The present study proposed a holistic procedure of combining both experimental and numerical investigations to conduct the fundamental study on coupled mechanical-electrochemical behavior of Li-ion battery. The proposed investigation highlighted the effect of stress on the capacity of the battery, considering capacity fade as an equivalent parameter to its health for real-time estimation of SoH. Finally, a simple model of Artificial Neural Network (ANN) is provided, which shows the linear dependency of stress with the SoH. The results obtained from the ANN model are validated with a Linear Regression (LR) model for a better understanding of the inspection. The predicted value of mean Square Error (MSE) and R square error in the ANN training model are found to be 0.000309 and 0.849687, respectively. Whereas for the test model, these predicted values are found to be 0.000438 and 0.819347, respectively.     

A future perspective on lithium-ion battery waste flows from electric vehicles

As a proactive step towards understanding future waste management challenges, this paper presents a future oriented material flow analysis (MFA) used to estimate the volume of lithium-ion battery (LIB) wastes to be potentially generated in the United States due to electric vehicle (EV) deployment in the near and long term future. Because future adoption of LIB and EV technology is uncertain, a set of scenarios was developed to bound the parameters most influential to the MFA model and to forecast “low,” “baseline,” and “high” projections of future end-of-life battery outflows from years 2015 to 2040. These models were implemented using technology forecasts, technical literature, and bench-scale data characterizing battery material composition. Considering the range from the most conservative to most extreme estimates, a cumulative outflow between 0.33 million metric tons and 4 million metric tons of lithium-ion cells could be generated between 2015 and 2040. Of this waste stream, only 42% of the expected materials (by weight) is currently recycled in the U.S., including metals such as aluminum, cobalt, copper, nickel, and steel. Another 10% of the projected EV battery waste stream (by weight) includes two high value materials that are currently not recycled at a significant rate: lithium and manganese. The remaining fraction of this waste stream will include materials with low recycling potential, for which safe disposal routes must be identified. Results also indicate that because of the potential “lifespan mismatch” between battery packs and the vehicles in which they are used, batteries with high reuse potential may also be entering the waste stream. As such, a robust end-of-life battery management system must include an increase in reuse avenues, expanded recycling capacity, and ultimate disposal routes that minimize risk to human and environmental health.     

Li-ion battery recycling and cobalt flow analysis in Japan

Batteries sometimes contain precious or toxic substances (e.g. nickel, cobalt, lead, mercury, cadmium). However, the collection and recycling rate of small batteries were low in Japan.We focus on cobalt in lithium ion (Li-ion) batteries and conduct chemical analysis, questioner survey and flow analysis in Japan.Results of chemical analysis showed that the concentration of cobalt in Li-ion batteries was around 20% regardless of the year manufactured or the manufacturer. As a result of the consumer questionnaire survey, it became clear that 70% or more of the small batteries are not being removed when small electronic products are finally disposed. The survey also revealed that recognition of the law and system for collection and recycling of small rechargeable batteries is approximately 30–40%. Substance flow analysis showed that both production and demand for Li-ion batteries (cobalt) have increased during 2002–2010. The collection rate for used Li-ion batteries was about 10% during this period; uncollected batteries were either stored or disposed through incineration and landfill as municipal solid waste.     

Productive utilization of pig farm wastes: a case study for developing countries

This paper presents a case study on pig farm waste management in which pig manure is stabilized in two-stage anaerobic reactors (to produce methane), while pig farm wastewater is treated in water hyacinth ponds from which the harvested water hyacinth plants are used in the production of silage (animal feed) or compost fertilizer. The results suggest the technical feasibility of applying these technologies to treat and recycle pig farm wastes. Cost/benefit analysis reveals the option to produce methane gas and silage to be financially viable after 15 years of operation. A management concept of waste recycling programs is presented, including relationships among objectives, constraints and implementation plan. Decision on a waste recycling program should not be based only on cost/benefit analysis, but also on the pollution control and public health improvement to be gained.     

Present status of the recycling of waste electrical and electronic equipment in Korea

In Korea due to rapid economical growth followed by urbanisation, breakage of large traditional families into small nuclear families, continuous changes in equipment features and capabilities causes tremendous increase in sale of new electrical and electronic equipment (EEE) and decrease in sale of used EEE. Subsequently, the ever-increasing quantity of waste electrical and electronic equipment (WEEE) has become a serious social problem and threat to the environment. Therefore, the gradual increase in the generation of WEEE intensifies the interest for recycling to conserve the resources and protect the environment. In view of the above, a review has been made related to the present status of the recycling of waste electrical and electronic equipment in Korea. This paper describes the present status of generation and recycling of waste electrical and electronic equipment, namely TVs, refrigerators, washing machines, air conditioners, personal computers and mobile phones in Korea. The commercial processes and the status of developing new technologies for the recycling of metallic values from waste printed circuit boards (PCBs) is also described briefly. Since 1998, three recycling centers are in full operation to recycle WEEE such as refrigerators, washing machines and air conditioners, having the total capacity of 880,000 units/year. All waste TVs are recently recycled on commission basis by several private recycling plants. The recycling of waste personal computers and mobile phones is insignificant in comparison with the amount of estimated obsolete those. Korea has adopted and enforced the extended producer responsibility (EPR) system. Korea is making consistent efforts to improve the recycling rate to the standards indicated in the EU directives for WEEE. Especially environmentally friendly and energy-saving technologies are being developed to recycle metal values from PCBs of WEEE.     

Electronic waste recycling: A review of U.S. infrastructure and technology options

The useful life of consumer electronic devices is relatively short, and decreasing as a result of rapid changes in equipment features and capabilities. This creates a large waste stream of obsolete electronic equipment, electronic waste (e-waste).Even though there are conventional disposal methods for e-waste, these methods have disadvantages from both the economic and environmental viewpoints. As a result, new e-waste management options need to be considered, for example, recycling. But electronic recycling has a short history, so there is not yet a solid infrastructure in place.In this paper, the first half describes trends in the amount of e-waste, existing recycling programs, and collection methods. The second half describes various methods available to recover materials from e-waste. In particular, various recycling technologies for the glass, plastics, and metals found in e-waste are discussed. For glass, glass-to-glass recycling and glass-to-lead recycling technologies are presented. For plastics, chemical (feedstock) recycling, mechanical recycling, and thermal recycling methods are analyzed. Recovery processes for copper, lead, and precious metals such as silver, gold, platinum, and palladium are reviewed. These processes are described and compared on the basis of available technologies, resources, and material input–output systems.     

干电池在食盐溶液中锈蚀及内容物外泄研究

废电池的潜在环境污染已日益受到广泛的社会关注。但是,目前废旧电池却还一直存在日常生活中,这将会对环境造成极大的潜在威胁。针对废电池中主要污染物的环境污染途径及主要污染危害进行了实验及分析。通过具体的实验,研究废旧电池中有毒有害物质在自然环境中泄露、传递过程,由此,为相关部门和相关行业提供实现生活垃圾分类收集以及固体废弃垃圾资源化的依据。     

Lithium availability in the EU27 for battery-driven vehicles: The impact of recycling and substitution on the confrontation between supply and demand until2050

The adverse impacts of climate change are widely recognized as well as the importance of the mitigation of carbon dioxide (CO₂). Battery driven vehicles are expected to have a bright future, since GHG emissions can be reduced. Lithium-ion (Li-ion) batteries appear to be the most promising, due to their high energy density. Recently, the discussion concerning adequate lithium carbonate (Li₂CO₃) resources is resolved. The current challenge is the needed increase in flow rate of Li₂CO₃ into society to foresee in forecasted demand. This research determines ten factors which influence the availability of Li-ion batteries for the EU27 in the coming decades. They are used in a system dynamics analysis. The results of this research show that undersupply can be expected in the EU27 until 2045 somewhere between 0.5 Mt and 2.8 Mt. Substitution of Li₂CO₃ in other end-use markets and recycling can relieve the strain on Li₂CO₃ supply to some extent. In 2050, 20% of the vehicle fleet in the EU27 can be battery electric vehicles (BEVs). The lack of resources in the EU27 and the geographical distribution of lithium in politically sensitive areas suggest that the shares of lithium available for the EU27 will be less than assumed in this research. The increase in flow rate shows to be the bottle-neck for a transition to (partly) battery driven vehicles in the EU27, at least when Li-ion batteries are used. Focusing on large-scale application of BEVs with Li-ion batteries in order to substantially mitigate CO₂ emissions in transport is a futile campaign.