recycling of li-ion and lead acid batteries & extraction of all by products

RECYCLING OF LI-ION AND LEAD ACID BATTERIES & EXTRACTION OF ALL BY PRODUCTS

[CODE NO.4424] 

Lead batteries industry in India is currently estimated at Rs 40,000 crore with 60% automotive and 40% industrial. The recycling activity in India is undergoing through thousands of players with recovery of lead from LABs from telecom, UPS, inverters, Non-conventional energy and other associated industries. India has two major primary lead producers namely Hindustan Zinc Ltd (HZL) and Indian Lead Limited (ILL) with an accumulative annual production capacity of 200,000 tonnes Recycling rates of lead acid batteries is increasing specially in develop countries such as United States, Japan and European countries. Nearly 95-99% of all lead acid batteries are recycled in United States. The utilization of lead acid batteries is growing day by day in Greece due to the increase in number of vehicles but only 80–85% of used lead acid batteries are collected and recycled. Whereas in china only 25% of used lead acid batteries are being recycled.

Indian lead battery industry comprises of 60% automotive and 40% industrial battery. In India the two major primary lead producing corporations namely Hindustan Zinc limited (HZL) and Indian lead limited (ILL) with a collective annual production capacity of 200,000 tonnes. The requirement of lead which is not ful?lled by primary production is accomplished by secondary production. LABs are the main source of old scraps. Used lead acid batteries are collected and have become a key source of secondary production. Automobile battery scrap contributes 80% of used scrap being recycled as secondary lead virgin material. 

India has 33 authorized battery recyclers and illegal sector is estimated to account for 60–80% of unscienti?c recycling. Different recycling rates of lead acid batteries in various states of India.

Used lead acid batteries have a high metal content and the recovery of lead from these wastes is a low energy, low cost operation. The recycling of lead waste, especially from batteries, by the unorganised sector causes (a) environmental damage to the surrounding areas as their recovery methods are inefficient and the optimum quantity of lead is not recovered, resulting in a considerable amount of lead entering the environment, and (b) it also endangers the health of the workers who are engaged in this activity. The MoEF notification in 2001 tried to arrest this practice by stipulating that all individuals, institutions and commercial establishments, such as dealers, manufacturers, etc. have to ensure that used lead acid batteries are handed over to authorised recyclers. Newspaper and NGOs, however, report that the recycling of used lead acid batteries is still flourishing in the unorganised sector, in India. On the other hand, industrialised countries, especially the USA and the EU have adopted policies whic

h have resulted in an effective recycling system. This dissertation will discuss ? The recycling policies in India, their structure, how they have evolved and how they are being implemented in a government institution the Railways.? A brief history of the lead industry, the usage of lead and its effects on human health.? The policies prevalent in industrialised and developing countries and how they have tackled the issue of used lead acid battery recycling in their countries.?The recycling policy in the context of the Indian Railways, with specific reference to the cost of disposal of batteries in the Railways and what effect the MoEF notification in 2001 had on battery disposal in the Railways. These studies and analyses will suggest that (a) an alternative policy that is based on cost-effectiveness will be most appropriate in the Indian context, and (b) there is a need for the immediate promulgation of a notification with respect to Ni-Cd batteries, and (c) the Indian Railways will benefit if it disposes of 

its used lead acid batteries directly to the manufacturer instead of selling it to secondary smelters, and government should increase custom duty on import of lead so that import of lead is discouraged.

Lead-acid batteries are a reliable and cost-effective uninterrupted power supply for cars, wheelchairs, and others. Recycling the spent lead-acid batteries has increased cost and could be a serious pollution issue after extensive use. It is important to exploit new-generation application to increase their value. In this article, we used a simple method for recycling spent lead-acid batteries for a useful lead iodide resource with a high purity of over 99% and a recycling yield of 93.1% and then fabricated multifunctional FAPbI3 perovskite diodes using recycled lead iodide (PbI2). 

The cost of recycled PbI2 based on lab-grade chemicals is estimated to be only 13.6% that of lab-grade PbI2, which undoubtedly greatly reduces the preparation cost of devices in the lab. The external quantum efficiencies of our perovskite diodes prepared with commercial and recycled PbI2 are 19.0 and 18.7%, respectively, which shows that the performance of the device prepared from recycled PbI2 is comparable to that of commercial lab-grade PbI2. Based on the expense of industrial-grade chemicals, the cost of recycled PbI2 is extrapolated to be 70.2% that of industrial-grade PbI2. Therefore, it can not only offer an approach to recycle hazardous solid waste but also save manufacturing cost of new-generation photoelectric devices, leading to earning additional value for lead waste.

Rapid growth in the market for electric vehicles is imperative, to meet global targets for reducing greenhouse gas emissions, to improve air quality in urban centres and to meet the needs of consumers, with whom electric vehicles are increasingly popular. However, growing numbers of electric vehicles present a serious waste-management challenge for recyclers at end-of-life. Nevertheless, spent batteries may also present an opportunity as manufacturers require access to strategic elements and critical materials for key components in electric-vehicle manufacture: recycled lithium-ion batteries from electric vehicles could provide a valuable secondary source of materials. Here we outline and evaluate the current range of approaches to electric-vehicle lithium-ion battery recycling and re-use, and highlight areas for future progress.

Battery specialists and environmentalists give a long list of reasons to recycle Li-ion batteries. The materials recovered could be used to make new batteries, lowering manufacturing costs. Currently, those materials account for more than half of a battery’s cost. The prices of two common cathode metals, cobalt and nickel, the most expensive components, have fluctuated substantially in recent years. Current market prices for cobalt and nickel stand at roughly $27,500 per metric ton and $12,600 per metric ton, respectively. In 2018, cobalt’s price exceeded $90,000 per metric ton.

In many types of Li-ion batteries, the concentrations of these metals, along with those of lithium and manganese, exceed the concentrations in natural ores, making spent batteries akin to highly enriched ore. If those metals can be recovered from used batteries at a large scale and more economically than from natural ore, the price of batteries and electric vehicles should drop.

In addition to potential economic benefits, recycling could reduce the quantity of material going into landfills. Cobalt, nickel, manganese, and other metals found in batteries can readily leak from the casing of buried batteries and contaminate soil and groundwater, threatening ecosystems and human health, says Zhi Sun, a specialist in pollution control at the Chinese Academy of Sciences. The same is true of the solution of lithium fluoride salts (LiPF6 is common) in organic solvents that are used in a battery’s electrolyte.

Batteries can have negative environmental effects not just at the end of their lives but also long before they are manufactured. As Argonne’s Gaines points out, more recycling means less mining of virgin material and less of the associated environmental harm. For example, mining for some battery metals requires processing metal-sulfide ore, which is energy intensive and emits SOx that can lead to acid rain.

Less reliance on mining for battery materials could also slow the depletion of these raw materials. Gaines and Argonne coworkers studied this issue using computational methods to model how growing battery production could affect the geological reserves of a number of metals through 2050. Acknowledging that these predictions are “complicated and uncertain,” the researchers found that world reserves of lithium and nickel are adequate to sustain rapid growth of battery production. But battery manufacturing could decrease global cobalt reserves by more than 10%.

COST ESTIMATION

Plant Capacity                                    11.1 MT/Day

Land & Building (10,000 sq.mt.)  Rs. 7.44  Cr

Plant & Machinery                             Rs. 1.64  Cr

Working Capital for 2 Months     Rs. 18.04 Cr

Total Capital Investment             Rs. 27.50 Cr

Rate of Return                                   67%

Break Even Point                               31%

• INTRODUCTION
  
• CHALLENGES IN RECYCLING LI-ION BATTERIES
• B.I.S. SPECIFICATION
• FOR LEAD ACID BATTERY:
• FOR LIB BATTERY:
• PROCESS FLOW CHART
• FOR LEAD ACID:
• FOR LIB BATTERY:
• RECYCLING OF LEAD ACID BATTERY
• (1) COLLECTION OF USED BATTERY
• (A) BATTERIES SHOULD NOT BE DRAINED AT COLLECTION POINTS:
• (B) BATTERIES MUST BE STORED IN PROPER PLACES AT COLLECTION POINTS:
• (2) TRANSPORTATION
• (3) STORAGE
• (4) BATTERY BREAKING
• 1. MANUAL BATTERY BREAKING
• 2. AUTOMATIC BATTERY BREAKING
• POTENTIAL SOURCES OF ENVIRONMENTAL CONTAMINATION
• (5) LEAD REDUCTION
• (A) PYROMETALLURGICAL METHODS
• DESULPHURIZATION
• THE QUANTITY OF FLUX AND REDUCING AGENT ADDED MUST BE CAREFULLY CONTROLLED:
• (B) HYDROMETALLURGICAL METHODS
• POTENTIAL SOURCES OF ENVIRONMENTAL CONTAMINATION
• (6) LEAD REFINING
• PYROMETALLURGICAL REFINING METHOD
• POTENTIAL SOURCES OF ENVIRONMENTAL CONTAMINATION
• SOME SOURCES OF ENVIRONMENTAL IMPACTS IN THE LEAD REFINING PROCESS ARE:
• (F) CASTING
• RECYCLING OF LITHIUM ION BATTERY
• 1. DISCHARGING
• 2. DISMANTLING
• METHODS OF LITHIUM EXTRACTION
• 3. PYROMETALLURGY
• 4. HYDROMETALLURGY
• 5. ELECTROCHEMICAL
• RECYCLING OF SPECIFIC COMPONENTS
• 1. ANODE (GRAPHITE)
• 2. CATHODE
• 3. ELECTROLYTE
• MARKET POSITION OF LEAD ACID BATTERY RECYCLING
• MARKET OVERVIEW OF LITHIUM-ION BATTERY RECYCLING
• COMPANIES OPERATING IN THE LITHIUM ION BATTERY RECYCLING  MARKET:
• GLOBAL LITHIUM ION BATTERY RECYCLING MARKET SEGMENTATION:
• BY CHEMISTRY
• BY SOURCE
• BY RECYCLING PROCESS
• BY GEOGRAPHY:
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT:
• EQUIPMENT LAYOUT:
• SAFETY:
• PLANT EXPANSION:
• FLOOR SPACE:
• UTILITIES SERVICING:
• BUILDING:
• MATERIAL-HANDLING EQUIPMENT:
• RAILROADS AND ROADS:
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• SPECIFIC FACTORS
• 6. TRANSPORTATION:
• A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• PLANT LAYOUT
• SUPPLIERS OF WASTE BATTERY SCRAP
• FOREIGN SUPPLIERS OF COMPELETE PLANT FOR RECYCLING OF BATTERY
• INDIAN SUPPLIERS OF BATTERY RECYCLING PLANT
• SUPPLIERS OF EOT CRANES
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)