Recycling of Photovoltaic (PV) Batteries - Revision history

Wiki Gardener: /* Further Information */

2015-05-20T11:06:39Z

Further Information

Ranisha at 11:57, 8 April 2015

2015-04-08T11:57:55Z

Wiki Gardener: /* Dismantling of Battery Cases and Feed Preparation */

2014-06-16T14:05:03Z

Dismantling of Battery Cases and Feed Preparation

Wiki Gardener at 14:04, 16 June 2014

2014-06-16T14:04:22Z

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Wiki Gardener: moved Recycling of PV batteries to Recycling of Photovoltaic (PV) Batteries

2012-06-27T09:01:35Z

moved Recycling of PV batteries to Recycling of Photovoltaic (PV) Batteries

Wiki Gardener at 09:00, 27 June 2012

2012-06-27T09:00:49Z

Wiki Gardener at 08:55, 27 June 2012

2012-06-27T08:55:21Z

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Uschuetzenmeister at 15:05, 26 June 2012

2012-06-26T15:05:33Z

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Katharina Meder at 13:44, 11 August 2011

2011-08-11T13:44:12Z

Patrick Nagel at 07:12, 1 April 2011

2011-04-01T07:12:52Z

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 <br/>
 = Further Information<br/> =
 *Presentation: [[:file:Reap batteries for pv systems-am.ppt|recycling systems for PV-batteries, Andi Michel, Addis Ababa, October 2008]]
-*[[:file:Fundamentals of the Recycling of Lead-Acid Batteries|Gate, GTZ: Vest, Heino: Fundamentals of the Recycling of Lead-Acid Batteries, 2002]](279 kB)
+*[[:File:Fundamentals_of_the_Recycling_of_Lead-Acid_Batteries.pdf|Gate, GTZ: Vest, Heino: Fundamentals of the Recycling of Lead-Acid Batteries, 2002]](279 kB)
 *Pv-batteries, Silvia Schubert
 <br/>
 = References<br/> =

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 = Overview =
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 *Presentation: [[:file:Reap batteries for pv systems-am.ppt|recycling systems for PV-batteries, Andi Michel, Addis Ababa, October 2008]]
-*[[:file:Infogate fundamentals of the recycling of lead acid batteries.pdf|Gate, GTZ: Vest, Heino: Fundamentals of the Recycling of Lead-Acid Batteries, 2002]](279 kB)
+*[[:file:Fundamentals of the Recycling of Lead-Acid Batteries|Gate, GTZ: Vest, Heino: Fundamentals of the Recycling of Lead-Acid Batteries, 2002]](279 kB)
 *Pv-batteries, Silvia Schubert
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 <references />
 [[Category:Solar]]

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-==== Dismantling of Battery Cases and Feed Preparation<br/> ====
 Used batteries are emptied by hand and the acid is collected in plastic barrels. If the full barrels are kept motionless for some time, solid impurities will settle at the bottom of the barrels. This process of sedimentation may be assisted by adding some flocculent. The purified acid is then decanted and packed for sale. Possible customers for the recycled acid is the mining and metallurgical industry which uses acid in various leaching operations. The remaining battery sludge is neutralised with lime. After passing through a filter press the filter cake may be charged together with the fine fraction into the melting and reduction furnace.
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 [[File:Fig3 Hammer mill.JPG|frame|none|256px|Hammer mill crushing whole batteries]]
+<br/>
 In both cases, the slurry is pumped continuously or batchwise to sedimentation tanks, where the solids settle at the bottom. The clarified liquid is returned back to the grinding operation, while the sludge at the bottom of the tanks passes a filter press or is left to sun-dry. The filter or sun dried cake is the main feed for the melting and reduction operation which will produce almost pure lead.
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 <br/>
 === Melting and Reduction Operation of Paste and Battery Fines<br/> ===

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 Lead-acid batteries are called secondary batteries or accumulators since they are rechargeable. They again can be divided into starter and industrial batteries. Starter and industrial batteries are used to provide large quantities of energy (e.g. to start a car, operate electric vehicles, as energy storage medium for solar applications, as short-term emergency power source, etc.). Units generally weigh from a few kilograms to one ton.
-In the lead-acid battery sector, starter batteries have by far the largest share. In 1995, approx. 96 million units were produced worldwide<ref name="Battery Council International">http://www.batterycouncil.org/</ref>. An annual production growth rate of 2% is expected. Especially in developing countries, where the number of cars is growing over-proportionately, high growth rates in the use of lead-acid batteries are to be expected. Studies carried out in Botswana indicate that the number of batteries used in the automobile sector will grow by 40-50% over the period from 1995 to 2005 (source: GTZ waste management project). If we consider China alone, the most populous country of the world, which currently starts to introduce private car transport, it is obvious that high growth rates in the consumption of starter batteries must be expected in the future, especially in developing countries.
+In the lead-acid battery sector, starter batteries have by far the largest share. In 1995, approx. 96 million units were produced worldwide<ref name="Battery Council International">http://www.batterycouncil.org/</ref>. An annual production growth rate of 2% is expected. Especially in developing countries, where the number of cars is growing over-proportionately, high growth rates in the use of lead-acid batteries are to be expected. Studies carried out in Botswana indicate that the number of batteries used in the automobile sector will grow by 40-50% over the period from 1995 to 2005<ref name="GTZ waste management project">GTZ waste management project</ref>. If we consider China alone, the most populous country of the world, which currently starts to introduce private car transport, it is obvious that high growth rates in the consumption of starter batteries must be expected in the future, especially in developing countries.
 Returning used lead batteries to the recycling loop has a long tradition. Thanks to the compactness of a battery, its high lead proportion (95%) and relatively high metal prices, it has been worthwhile for consumers to return their own or collected car batteries to the scrap trade or secondary smelters. The return rate of spent batteries was thus already high in times when catchwords such as resource conservation and environmental protection, recycling, closed-loop materials management etc. did not yet play a role. Even today, the success of lead battery recycling in developing countries continues to be determined largely by the potential earnings of scrap collectors and traders. In industrialised countries, statutory requirements to take back spent batteries have compensated for the loss of economic incentives in spent battery return.
-In most European countries, battery retailers are under obligation to take back spent batteries. Lead batteries also come from repair workshops, the reprocessing of scrap car bodies and at municipal collection centres. In Germany, for example, this well functioning and effective collection system has led to a return rate of more than 95% for starter batteries and almost 100% for industrial batteries. In developing countries, too, return rates of up to 80% can be achieved where buyingup structures for spent batteries are in place. In Zimbabwe (source: Central African Batteries) for example, the entire demand for local battery production is covered by recycling of used batteries.
+In most European countries, battery retailers are under obligation to take back spent batteries. Lead batteries also come from repair workshops, the reprocessing of scrap car bodies and at municipal collection centres. In Germany, for example, this well functioning and effective collection system has led to a return rate of more than 95% for starter batteries and almost 100% for industrial batteries. In developing countries, too, return rates of up to 80% can be achieved where buyingup structures for spent batteries are in place. In Zimbabwe<ref>Central African Batteries (Pvt) Ltd </ref> for example, the entire demand for local battery production is covered by recycling of used batteries.
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 == Environmental Considerations<br/> ==
 As already mentioned, the potential health and environmental risk involved when processing battery scrap is very high.
 <u>Depending on the level of mechanisation and environmental standards, the following environmental hazards can arise:</u>
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 <references />
 [[Category:Solar]]

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 '''Existing Documents:'''
-*Presentation: [http://energypedia.info/images/6/61/Reap_batteries_for_pv_systems-am.ppt recycling systems for PV-batteries, Andi Michel, Addis Ababa, October 2008]
+*Presentation: [[:file:Reap_batteries_for_pv_systems-am.ppt|recycling systems for PV-batteries, Andi Michel, Addis Ababa, October 2008]]
-*[http://www.energypedia.info/index.php/file:Infogate_fundamentals_of_the_recycling_of_lead_acid_batteries.pdf Gate, GTZ: Vest, Heino: Fundamentals of the Recycling of Lead-Acid Batteries, 2002 ](279 kB)
+*[[:file:Infogate_fundamentals_of_the_recycling_of_lead_acid_batteries.pdf|Gate, GTZ: Vest, Heino: Fundamentals of the Recycling of Lead-Acid Batteries, 2002 ]](279 kB)
 *Pv-batteries, Silvia Schubert

← Older revision	Revision as of 09:01, 27 June 2012
(No difference)

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 In most European countries, battery retailers are under obligation to take back spent batteries. Lead batteries also come from repair workshops, the reprocessing of scrap car bodies and at municipal collection centres. In Germany, for example, this well functioning and effective collection system has led to a return rate of more than 95% for starter batteries and almost 100% for industrial batteries. In developing countries, too, return rates of up to 80% can be achieved where buyingup structures for spent batteries are in place. In Zimbabwe (source: Central African Batteries) for example, the entire demand for local battery production is covered by recycling of used batteries.
 <br>
 == Battery scrap – raw material for recycling  ==
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 PbO2 + Pb + H2SO4 → 2PbSO4 + 2H2O
 <br>
 Older types of batteries have a hard rubber casing and PVC (polyvinylchloride)- separators instead of casings and separators from PP. In some developing countries (e.g. Zimbabwe) these types of batteries are still produced and in use. [[Image:Tab1. Battery Comp.JPG]]
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 ''Tab. 2: approximate composition of Pb-bearing components of a starter battery''
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 The grids of old types of batteries have a higher Sb (antimony)-content (~4%) than the modern maintenance-free batteries (~2%), which instead add Ca(calcium) 0,5% to their grid alloy.
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 Some secondary smelters also buy up pre-sorted battery fractions, e.g. grids and lead paste without casings and separators, in addition to complete batteries. The lead smelters thus save several processing stages and do not have to deal with casing and separator wastes. They are therefore willing to pay a higher price for the material supplied. This practice is very harmful in environmental terms. Through the dispersed pre-sorting activities, lead-containing residues and wastes arise in many places and it becomes impossible to control their proposal.
 <br>
 === Metallurgical aspects of lead recycling from battery scrap  ===
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 PbSO<sub>4 </sub>lead sulphate, part of the&nbsp;paste
 <br>
 While the first component needs only melting, the two other components have to be converted by chemical/metallurgical processes to obtain lead metal, which takes place in the furnace.
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 PbS + PbO<sub>2</sub>&nbsp; -&gt; 2 Pb + So<sub>2</sub>
 <br>
 The above mentioned chemical reaction are sum reaction. That means that there are intermediate steps in between. The reactions take place in the melting furnace at high temperature (900-1200 °C) and need additives, which are . carbon (in the form of coal) and iron (in the form of iron swarf). Impurities are collected in the slag which requires for example soda ash as liquidifying and slag forming constituent. The product of the smelting operation is crude lead, which needs subsequent refining, and soda slag as residue. Since soda slag is water soluble and therefore hazardous when brought to landfills, modern lead recycling plants use silica slag (fayalite slag), which is water insoluble. It requires, however, a much higher furnace operation temperature of approximately 1400°C.
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 ''Fig. 7: Off-gas cleaning system of a lead recycling furnace in Zimbabwe''
 <br>
 From the furnace the hot gases pass through a hot dust chamber and/or a hot cyclone where most of the coarse dust particles are separated from the gas stream. From there the off-gas feed into a wet gas cleaning system which consists of a venturi washer and a wet scrubber.
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 • open tipping of residues and wastes such as battery casings and PVC separators.
 <br>
 Workers, too, are exposed to raised levels of harmful substances in such facilities. This generates considerable health risks if appropriate precautionary measures are not taken (respiratory equipment, washing facilities, separate eating and resting rooms, regular examinations, etc.). <br>
 <br>
 <br>
 <br>
 '''Existing Documents:'''
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 *Pv-batteries, Silvia Schubert
 <br>
 <br>
 [[Category:Solar|<font color="#002bb8">Solar</font>]]