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UNEP IndustryandEnvironment
Environmental and
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related to
Lead-Acid
BaDen Recvcling
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Environmental and
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8 Lead-Acid Ballerv
Recvcling
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UNEP
UNITEDNATIONS ENVIRONMENTPROGRAMME
lNDUSTRY AND ENVIRONMENT
39-43, QUAI ANDRE CITROEN
75739 PARIS CEDEX 15-FRANCE
TEL: (33)0144371450
FAX: (33) 0144 371474
E-MAIL : unepie@unep.fr
hup:/ /www.unepie.orgibome.html
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UNEP TrainingUnit A WorkbookforTrainers
This workbookis oneof a seriesthat providespracticalsupportmaterial to
teachersandtrainerswishingto commenceor enrich their curriculum with
up-to-dateapproachesin environmentalmanagement.
It is basedon extendedexperiencewith training workshopsby UNEP and
ailier agencies,andis now beingmadeavailablefor wider use in all
regionsthroughouttheworld.
UnitedHationsPublication
1 ISBN 92-807-1611-5 1
.)
8
Table 01 Contents
Environmental and Technological Issues
related to Lead-Acid Battery Recycling
Evaluation Form i
Users Guide iii
Glossary v
Part 1 Introduction
1.1 This package 1:4
1.2 Contents ofthis package 1:5
Appendices
1 Supporting Documentsfor this Package , 3
Il List of Training Resource Packages availablefrom UNEP IE 5
/II About UNEP lndustry and Environment , 7
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8
Users Guide
8
Do not forget to refer also to the package on Cleaner Production for teaching the underlying concepts
and approaches in ibis workbook.
F inally, we must stress again that ibis package does DOt cover aIl aspects of the subject.
Its prime purpose is to lead trainers into ibis field, and to help and encourage them to develop
their own material, appropriately tailored to their specific leaming situation. UNEP is prepared to work
further with trainers who wish to extend ibis package into new directions, or go into greater depths
on some subjects.
,.~.."'&'",."...
iv United Nations Environment Programme' Industry and Environment
1 Remember tl,at this is a starters kit, not a 3 Refresh your memory by reading some of the
complete recipe book. Remember also that the background papers and studying the overhead
workbook aims to develop insights and decision- transparencies. Write rOUf own notes in the
making skills, not to convey knowledge or facts. spaces provided.
This is the task of the references listed separately. 4 IdentifY some expert resource persons who
2 Understand the needs ofyour trainees. What could be invited as rotors to help you in
insights or ski Ils do you intend to develop? discussion sessions.
Defme rOUf learning objectives.
5 Select some ~f tl,e exercises you wish to 7 DeveloP other exercises or questions ')
present to tramees. yourself.
6 Examine carefully the case study or 8 Develop your own local case study ifyou can,
scenario on which they are based. Be sure and use this instead of the one in the pac}<age.
that you have at least one solution to the exercise 9 prepare some background questions and
that you can explain and defend. preliminary exercises for trainees to carry out
before they start the workshop/course.
1 Q In session, summarize tl,e issues for a rotor. Discuss and compare results. Be open
trainees using the overheads given, and to ideas and experiences from trainees, and
others you may have. Discuss the problems and discuss these.
difficulties decision-makers face. Discuss where 12 Return to tl,e learning objectives, and
factual information can be found to help in check that they have been achieved.
)
Refer also to otl,er packages and workbooks, wl,ere useful additional teaching material is found.
To facilitate using this workbook, the header of odd-numbered pages describes the contents of that
particular section. This information is also repeated in the footer of even-numbered pages. You can crack
rOUf progress through the workbook by referring to the calibrations on the bar across the bottom of odd-
numbered pages:
)
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers
v
e
Glossarv
T his glossary contains some of the tenns round in the background papers or in other papers
conceming lead-acid battery recycling. This glossary is Dot complete and you may want to add
further items.
Thefol/owing sources have been used: Environment Canada,UNEP lE, Greenpeace,and The
Environmental Glossary (D. Dooley, K. Patrick)
APELL Awarenessand Preparedness for Emergencies performingwith the aimof helpingto safeguardthe
at a Local Level. environmentby: (i) facilitating management contraIof
Bag filter Nameof a type of filter usedfor extracting environmentalpractices;and (ii) assessing compliance
airbome dustfrom the atrnosphere. with companypolicies,whichwould include
e Basel Convention TheBaselConventionon the regulatoryrequirements.
Control ofTransboundaryMovementsofHazardous Environmental impact assessment An analysisto
Wastesand their Disposai (1989)aimsto contraIthe determinewhetheran actionor projectwould
transboundarymovementand disposaIofhazardous significantlyaffectthe environrnent.
wastes. Good housekeeping Efficient management of the
Battery breaker A preliminary processorof batteries propertyand equipmentof an institutionor
thatappliesa varietyof techniquesto breakthe organization.ln the contextof cleanerproduction,it
battery,drain the sulphuricacid from the battery oftenrefersto the proceduresapplied in the operation
cavity,removeplasticand sellthe leadcomponentsto of a productionprocess.
the smelter.Batterybreakersmaybe independent Grid Metallic grille-like structuralframeworkin a
businessesor encompassed in secondarysmelting battery.Its purposeis to supportthe active material
operations. and conductcurrentto the cell terminais.It is cast
Cleaner production The continuousapplicationof from a high purity leadalloyed with approximately
an integratedpreventivestrategyto processes and 5%to 12%antimony,0.5%tin, anda fewhundredths
products,in orderto reduceenvironmentalrisks peTcentof coppeT andarsenic.
and impacts. Heavy metals Metallic elementswith high atomic
" Ch""- ~.
vi United Nations Environment Programme' Industryand Environment
Matte Molten materialin the courseof the recovery entrainedor absorbedin the waterand ",)
processin a smelter:it is not completelypure metal so easilycontrolled.
and requiresfurtherprocessing. Secondary lead Lead which bas beenused for
Ore A mixture of mineraIsand a ganguefrom which at differentapplicationsfor which it basno longerhas
leastone of the mineraIscanbe extractedat a profit. a purpose,and which is to be recycled.
Paste The mixture of leadoxide andlead sulphate, Secondary lead smelter The metallurgicalprocess
originatingfrom the lead-acidbatteries. that remeltsor refineslead ingots,or lead-containing
Pollution The termdescribesthe presenceofharmful, scrapofvarious types,andproduceslead compound
hazardousor detrimentalconstituentsin an which is furtherprocessed.
environment.A polluted environmentdescribesastate Separator PVCplatesfunctioning as isolatorsto keep
that occurswhenthe assimilativecapacityof the the anodeandthe cathodefrom direct electrical
environmentis exceeded,resulting in undesirable contact.It is porousenoughto retainsulphuric acid
ecologicalchanges. and allowelectric currentto flow betweenthe plates.
Primary lead purification Originating from oresor Slag Solid wasteproducedfrom a metallurgical
concentrates.High temperatureprocesswherelead fumace.It is predominantlynon-metallic
oxide drossesarereducedto metallic leadand in composition.
impurities,suchas iron, arsenic,antimony,and SU battery StartingLighting and Ignition batteries. ...
tin areremovedin slags. Theyareusedin cars,trucks,and buses. :)
Raw material A materialon which a particular Smelting The partial recoveryof metal in molten form.
manufacturingprocessis carriedout. Smeltingis requiredto recoverthe metal contentand
Reclamation recycling The recoveryofuseful convertit to a form that is readyfor refining.
productsfrom wastematerials.The retrievalof Sustainable development Meetingthe needsof the
materialsor productsfor re-usein their original form presentgenerationwithout compromisingthe ability
or for reprocessinginto otherproducts. of future generationsto meettheir needs.
Recovery The extractionof materialfrom wastethat Sweating The processwherethe moltenlead is
may be recycledor reused.Recoverymaytake place separatedfrom the varioustypesof scrapcontaining
at the sourceofwaste productionor as a process both metallic andnon-metallicimpurities.The process
duringwastehandling. is executedin a reverberatoryfumace.
Refining Removingofmetals which are not desiredin Technology assessment A study or evaluationto
the end productby addingreactantswhich form helpunderstandthe likely impactof the useof a new
drosseswith the unwantedmetals.The drossesare technologyby an industryor society.
then skimmedoff. Used lead-acid battery A lead-acidbatterythat bas
Reuse Retrievalof materialor productsfor its original beentakenout of servicebecauseit is spent,due to
purposewithin the samesite. ln caseof lead.acid temporarybatteryfailure, discharge,car scrapping,
batteries:ensuringthatno batteryis takenoutof etc.Usedlead-acidbatteriespresentan environmental "
serviceuntil it canno longerbe servicedand used. and healththreatwhen improperlydisposeddue .,";
Reuseefforts presentlyfocus on reconditioningand to corrosiveness and potentialtoxicity of
rechargingbatteriesto extendtheir usefullife. componentparts.
Scrap Discardedmaterialfrom manufacturingor Wrecking The processduring which the batteryis
processingor remnantsafter anarticle'susefullife bas crushedinto smallerfractions.The sulphuric acid is
fUnout. Lead scrapis of threetypes:whole battery separatedfirst after which, optionally,the crushed
scrap,industrialscrap(suchas drosses),and other batterycanbe separatedinto the following fractions:
scrap(suchascablesheathings). lead grids,lead paste,polypropylene,PVC,
Scrubber Device for flue gascleaning.If dustandgas andebonite.
coli ideor contactwith water,they will become
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Part 1
Introduction
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1 Introduction
8 "'"'"'"'"'"'"'c""'AWorkbookfOr
Trainers
: Environmentaland Technologicallssues relatedto Lead-Acld Battery Recycllng
1:4 United Nations EnvironmentProgramme' Industry
andEnvironment
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Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
Part 1 .Introduction
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105
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8 the exercisesin Part 50The packagecanalsobe Ali partsof the packagecanbe usedfor
usedto preparea presentationon lead-acid preparingsucha workshop,althoughsomeof the
batteryrecyclingand its environmentalimpacts. exercisesmaybe time consumingo
The backgroundreadingsandthe transparencies Thirdly, the packagecan functionasa resource
providethe necessaryinformationfor fuis for teachersto includethe topic in existing
purposeoIt givesthe trainerenoughbackground curriculafor undergraduate studentswho havea
materialandtools to preparea threeto four technicalbackground.Part 4 of the packagecan
hourworkshopo be especiallyusefulfor fuis purposeo
8
1:6 United Nations Environment Programme. Industry and Environment
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Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkboak for Trainers
Part 1 .Introduction
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Part 2
Organizing Enective
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2 Organizing EUective
Training Activities
2.1 Introduction
8
C ommunication and organizationalskiIls
arejust as importantasa technical
Accordingly,this packagerelies on interactive
teachingmethods,usingworking exercises,case
appreciationof the subject.Professional studies,and groupworkproblem-solving,rather
educatorsalreadyunderstandthis point, but thanon lectureformat.
teachingis a very individual matter,and Interactivetechniquesaremore complexto
interactiveteachingcanbe very demandingon a organizethansimple lecture-giving,but theygive
busyperson. betterresults.ln particular,interactivemethods
Here,we recallsomeof the key aspectsof the aremore likely to providestudentswith practical
leamingprocess. skills. This is importantwhereskill development
This text containssuggestionsabout: ratherthan factualknowledgeis the objective.
.how to ensuremaximumeffectiveness as a Lecturesare betteratproviding factual
trainer knowledgethan at developingskills.
.how to organizeeffectivetraining activitiesand For example,a workshopformatis very
presentations. effectivein providingtraining onthe effective
We haveprovidedthis advicebefore useof management tools suchas Environmental
considerationof the technicalmaterial,so that ImpactAssessment (ElA), or audits.For high
readerscanremindthemselvesof the importance level environmentalmanagement, both
of the advicewhenchoosingwork exercisesand knowledgeandskills are required,so the
8 training projects,later in this package. appropriatemixture of techniquesshouldbe used.
Thenotesin this Partarebasedon the
Adults learn bestwllen tlleyare act;vely experiences ofUNEP lE and WHO in organizing
engaged.They remember20%of whatthey hear, workshopsand othertraining sessions.
40% ofwhat theysee and80% ofwhat they Personaladviceon howto be aneffective trainer
d. fi th 1' is also givenby severalexperiencedtrainers,who
lscover or emseves.
aIl useinteractivetraining approaches.
8 cc """'AWorkbookforTrainers:Ènvironmentai
andTechnological
Issuesrelatedto Lead-AcidBatteryRecycllng
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Il:4 United Nations EnvironmentProgramme' IndustryandEnvironment
2.2.1 Workshops
W orkshoPsprovide a stimulatingleaming .preparationof a countryreportby each
environmentwherepeoplewith a wide participantbeforethe workshop
rangeof experiencesand skills canjoin together .short introductoryor overviewlectureson key
to addresspracticalproblemsbeyondthe ability issues
of an individualto resolve. .practical problem-solvingwork exerciseson
Interactiveworkshopsusea combinationof casestudies
severaltechniquesto bring abouta deeperand .feedback by expertsand discussionson
morepragmaticleamingexperiencethan is workshopexercises
possiblewith a lecture-styleformat. .panel sessions(that is, question-answer
Workshopsalsoprovide excellentopportunities dialogues)with experts
for exchangingpersonalexperiences, problem- .individual studysessions,computerquizzes,
solving throughpanelsessionsand direct andso on.
consultationswith experts,anddiscussingsome .structured oral presentationsof countryreports ._~)
of the complexsituationswhich surroundmost leadingto a regionaloverview "
2.2.2 Preparation
Sparticipants
essionsneedto be carefullyprepared,with
knowing in advancewhatthey It cannotbe overstressedhow important it is
will do or see.A proformareportform for that participantsshouldbe thoroughly prepared
countryreportsgivesa commonformatto these for the workshops,and tllat ail tl,epre-
sessions.Countryreportsshouldalso try to link workshopactivitiesI,avebeencompleted.
the issueswith othersessions.
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Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers ).
8
2.3 Someideas lor more enective communication
I f the training is to be successful,effective .trainees who are traditionally used to lectures
communication is essential- from recognition are suddenly required to take part in discussion
of the training need to the final evaluation of the groups, which might feel alien to them.
event. Most of these issuescan be anticipated and
Without good communication, aIl manDerof overcome by good communication between the
things can go wrong: course designers,writers, and event organizers
.the training is too early -or too late -to make and presenters on the one side, and the students
any impact on performance and their organizations on the other.
.trainees do not know what the training is about Some simple communication considerations will
or what to expect help to improve outputs in training and avoid
.the course is planned for a local public holiday disasters.
8
Issues related to Lead-Acid Battery Recycling
Il:6 United Nations Environment Programme' Industry and Environment
T he following
different
suggestions
in character, and
corne
therefore
from four
in teaching
teachers with
approaches.
long experience
However, they
in training.
ail believe
They
in an
are ail
.Provide an enjoyable learning situation that expands .Is fully acquainted with, and believes in, the
.Model
you think
courses
are outstanding.
and teaching Askstyles
yourself
on examples
about the that .Utilizes
and motivate
clear the
and students
graphic to
illustrations
learn. to inform '":)
qualities of a good instructor or a good course, and .Utilizes learning approaches including multi-
follow the answers you corne up with. media, projects, interviews, questionnaires,
.Allow the subject matter to be discussed and debates, and similar interactive approaches to
discovered by students -not hammered in. ensure full involvement of the students.
.Make courses relevant and interesting by .Reacts positively to aIl questions -there are no
understanding your audience. Ask them what they Stupid Questions, only Stupid Answers.
already know, and then plan for their needs. .Remembers that positive reinforcement is a
Incorporate ideas from the group in the course. better motivational approach than criticism.
.Remember that no amount of style will substitute for .Is available for private discussions with
effective ('doing the right things:J: .Likes the learners, and has a true understanding of
.Think about helping people to learn, rather than how they learn.
.Set learning lime limits. .Is stililearning, and has recent applied experience of
;~
Environmental and Technologicallssues related to Lead.Acid Battery Recycling : A Workbook for Trainers )
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3
as possible,etc.
During the initial groupmeeting,it is
importantto setan informai andfriendly
4
to be accomplishedby the endof eachpart.
IfYOUrgroupgetsinvolved in.diverseissues,
try to steerthembackon the nght track by
atmosphere.It is suggestedthatyou: askingrelevantquestions,ratherthantelling
.introduce yourselj; preferablyaskingeveryone themwhatto do.
to cali you by your first name,and then let 5 Give technicalassistanceand
everybodyintroducehimself/herselfin a similar supplementaryinformation as needed,
manner.Do not wasterimestatingpositions
8 Recycling
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Il:8 United Nations Environment Programme' Industry
andEnvironment
6
discussionprocess.
AlthOUghyou needDotstar with rOUfgroup
9 seeto it that you comparenotes,exchange
hints, and sharestrategieswith other
for 100%of the lime, it is expectedthatyou: resourcepersonsso that you can assistone
.spend at least80% afthe time with themduring another,asweil asgaugerOUfgroup's progress
regularsessions.The crucialtimes are atthe in comparisonwith the others.
beginning, middle,andnearthe endofeach 1O Iftension or heatedargumentarises
groupworksession. arnongyour groupmembers,try rOUf
.Ifthey decideto work beyondthe prescribed best(with a senseofhumor) to defuseit.
regulartime,just makesurethat theyare onthe
right track; your presenceduring overtimeis
Il ln the caseof absenteeism,approachthe
person/persons in questionand encourage
not mandatory,but voluntary. themto participate.
7 Therewill be critical parts during the
identificationof options,followed by
12 If one or two groupmembersare
dominatingthe discussionsor doing ail
technical,environmental,andeconomic the work, interveneandencourageeveryoneto
evaluation,whererOUftechnicaladvicewill be cet involved.ln orderto do fuis effectively, you .,~
mostneededby rOUfgroup. needto be attunedto rOUfgroup's 'culture' and )
The bestway to assistthe participantsis by trendof discussion.
giving only the advantagesand disadvantages of 13 Although division oflabor is a lime
the options in question.Let them weighthese savinggroupwork strategy,you must
pros and consanddecidefor themselveswhether ensurethat it is DOtdoneto the extentthat there is
to take or dropthe option. no peerlearningand discussionoccurring. It is
8 Ifyou encounterany questionaboutthe counter-productivefor groupmembersto work
technicalcontentof the materialthat you individually ontheseexercises.
have not beenbriefed on, discussit with the
TeamLeaderandagree on how to tackle tl,e
14 The mostproductive,meaningfuland
fulfilling groupwork is whenthey gel to
situation. It may weil be thatthe otherresource accomplishwhatthey haveto do as a team-and
havefun in theprocess!
Environmental and Technologicallssues related to Lead-Acid Battery Recycling: A Warkbaak for Trainers ...:,,)
Part 2 .OrganizingEffectiveTrainingActivities
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8 .Read the introduction, but avoid any sections on organizing training events.
.Seek out the section containing background papers or subject content. Read through
the whole section as narrative.
.Work through the pagesoffered to the trainer for overheadprojection, and ensure
you can relate the key points of eachoverheadto the text you have read.
.Look at the section on exercises. Identify those which lend themselvesto individual
work, and tackle them. Those exercisesclearly constructed for teamwork, or
requiring research, may not be appropriate.
.Refer back to the narrative text as and when you need to, to complete the exercises.
.Check your answers againstthose given in this resourcepack. Where there are
discrepancies, check through your own working to understandwhy the
discrepanciesappeared.
8 .Use the Appendices to plan your own further development.
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Il:10 United Nations Environment Programme. Industry and Environment
.1
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Transparencies
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1 1 5 Thickener
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111:82 United Nations Environment Programme. Industry and Environment
.Burnout of organic
contaminants (e.g. rubber,
PVç, polypropylene, paper,
etc~)
Most current lead smelters separatethe plastics fractions from the lead fraction during the wrecking
section. The plastic is hardly usedas a fuel any more during the smelting phase. Reagents (soda, CaO,
Si02, and Fe-chips) are added in drder to reduce the lead oxide and the lead sulphates (lead paste) to
minerallead.
Some smelting operations are preceded by desulphurization to reduce the generation of S02. There are
many different furnaces which can be used for the smelting process. Some of the most commonly used
are: the rotary reverberatory furnace, the blast furnace, and the stationary reverberatory furnace.
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
Part 3 .Technical Background Papers: Transparencies
This transparency gives a schematic presentation of a tYpical smelting section.
The case-study on the lead-acid battery recycling facilitY in Part 5 ofthis traîner package also refers to
this tYpical smelting operation.
A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
111:84 United Nations Environment Programme. Industry and Environment
Remelting, alloying, and refining is carried out batch-wise in pot and kettle fumaces. Depending on the
demand, the products of refining are either liard or soft /ead. For copper removal, the temperature of the
molten lead is allowed to drop to 320.C and sulphur is added.
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
.
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111:85
Transparencies
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This transparency gives a schematic presentation of a typical refining section. The case-studyon the
lead-acid battery recycling facility in Part 5 ofthis traîner package also refers to this typical refining
operation.
.
3--~'
111:86 United Nations Environment Programme' Industry and Environment
These options were produced asjPal1of a US AlD project, aimed at introducing cleaner production
approaches and measures into Tu isian industries. Of course,the options presented here are flOt
necessarily feasible or possible in ail secondary lead smelters.
Cleaner production measures ar pro-active, i.e. they aim to prevent pollution rather than to clean it up
at the 'end-of-the-pipe'. The cI ~ er production approach,promoted by UNEP lE, is worth considering in
ail industries, including second lead smelters. There is a Training Resource Package available on
cleaner production from UNEP 1 .
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Part 4
Information Sources
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A Wor/{boo/{ for Trainers : Environmental and Technologicallssues related to Lead-AêidBatte~'Re~ycîi~g
8 4 Information Sources
4.1 Introduction
P art 4 contains some references to infonnation sources on lead-acid battery recycling in particular,
and on recycling in general. It also contains infonnation about:
.background documents on lead-acid battery recycling,
.handbooks on chemicals, humans and the environment,
.audiovisuals.
A reference list on general environment related issues is also included, in casethe trainer requires more
8 infonnation on the most important environmental issuesoftoday.
42 Sources of information
United Nations Environment Programme: United Nations Industrial
Industry and Environment (UNEP lE) DevelopmentOrganization (UNIDO).
UNEP lE provides a query response service, UNIDO provides an infonnation database:the
answering technical and general requests for Industrial and Technological Infonnation Bank
infonnation and documentation related to (INTIB) of UNI DO.
industrial pollution. Further information:
Further information: INTIB, UNIDO, PO Box 300,
UNEP lE, 39-43 Quai André Citroën, A-1400 Vienna, Austria.
75739 Paris, Cedex 15, France. Tel (43 1) 21131/3705; Fax. (43 1) 2307584.
Tel (33 1) 44 37 1450; Fax (33 1) 44 37 1474. Battery Councillnternational
UNEPInternational Register of III E Wacker Drive, Suite 600, Chicago,
Potentially Toxic Chemicals (IRPTC) Il 60601, USA. Tel (1 312) 644 6610.
8 Provides infonnation on chemicals, waste EP3(Environmental Pollution
disposaI and discharge regulations, including the Prevention Project Clearinghouse)
current internationallist ofbanned or severely The EP3 Clearinghouse is an infonnation
restricted chemicals. service that collects, compiles, and assesses
Further information: technical reports, books, journal articles, and
UNEP IRPTC, Palais des Nations, other materials on pollution prevention, and
CH 1211 Geneva 10, Switzerland. disseminates them to businessesand govemments
Tel (41) 22 979 91 Il; Fax (41) 22 797 34 60. in developing countries. The Clearinghouse also
UNEPIWHO/ILOInternational Programme provides infonnation on a broad range of
for Chemical Safety (IPCS) environmental issues,and works with
Toxicological infonnation on chemicals. INFOTERRA/USA to obtain current worldwide
Further information: environmental infonnation.
IPCS, cIo World Health Organization, Further information:
CH 1211 Genera 27, Switzerland. EP3 Clearinghouse, 1530 Wilson Boulevard,
Tel (41) 22 791 Il; Fax (41) 22791 0746. Suite 900, Arlington, VA 22209-2406, USA.
Tel (1703) 3514004; Fax (1703) 3516166.
8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
,
Environmental and Technologicallssues related to Lead.Acid Battery Recycling : A Workbook for Trainers ..)
8
4.3 Documents on lead and
lead-acid batteries recvcling
Advances in Recovery and Recycling: Concepts Lead Astray: the poisonous lead battery waste
and Technology Volume III [1993] trade [1994] Greenpeace
M.E. Henstock; H.R. Skov (Eds.) This publication contains basic infonnation on
Collected papers of the REC '93 International the lead tracte and recycling practices. It also
Recycling Congress, Geneva, Switzerland discusses the impact of the lead tracte in
Volume III of the collected papers contains a developing countries. The discussion is based on
paper explaining the recycling of lead. Since research done on lead recycling practices and the
more than 50% of ail recycled lead originates environmental and health impacts of lead
from used lead-acid batteries, this is an recycling in six developing countries.
interesting article which introduces the reader to Further information:
recycling schemes and the technology of lead Greenpeace, Toxic Trade Publications,
8 smelting. 1436 U St NW. Washington,
Further information: D.C. 200009, USA.
Hexagon Ltd., P.O. Box 80, Tel (1 202) 462 1177; Fax (1 202) 462 4507.
DK-IO03 Copenhagen K, Denmark. Productivity and Low Waste Technology for
Guidelines for the Management of Used Lead.Acid Reprocessing Battery Scrap [1989]
Batteries in Canada [1993] K.F. Lamm; A.E. Melin.
This publication contains a description of the ln: Productivity and Technology in the
current battery management process in Canada, Metallurgicallndustries. The Minerais, Metals
together with a set ofrecommended practices for and Materials Society.
promoting consistency in the management of Recycling Lead And Zinc:
used lead-acid batteries across Canada. The Challenge of the 1990s [1991]
Further information: Proceedings of the conference organized by the
Environment Canada, Hazardous Waste International Lead and Zinc Study Group Sub-
Division, Office of Waste Management, Committee on Recycling, held in Rome, Italy, on
Place Vincent Massey, 12th Floor, 11-13 June 1991.
351 St. Joseph Blvd., Hull, The proceedings contain papers covering the
Quebec, K14 OH3, Canada. principal aspects ofrecycling:
8 Hazardous Waste: Detection, Control, Treatment .trends in world supply and demand for lead and
Part B [1988] R. Abbou (Ed.) zinc;
Proceedings of the World Conference on .the role of the secondary sectors;
Hazardous Waste, held in Budapest, Hungary, on .the extent of the recovery;
actober 25-31, 1987. .existing and developing recycling technologies;
The proceedings contain an article on a modem .environmental and health concerns and the
and low-pollutant secondary lead smelter to be regulatory framework.
set up in Hungary, and an incineration feasibility Further information:
study for battery plant trash and cru shed rubber International Lead and Zinc Study Group,
battery cases. 58 St James's Street, London SWIA lLD, UK.
Further information: Tel (4471) 4999373; Fax (44 71) 4933725.
Elsevier Science Publishers BV,
Sara Burgerhartstraat 25, P.O. Box 211,
1000 AE Amsterdam, The Netherlands.
8
A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
-
1V:6 United Nations Environment Programme. Industry and Environment
8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
Iv:8 United Nations Environment Programme' Industryand Environment
'"
4.5 Audiovisuals )
..
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers ~
~
Îil IV:9
8 IChemEhasaninternational
reputation
for providing
highquality,effective
safetyandenviron
mentaltrainingsolutions
usingvideo,slide,openlearning
andcomputer-basedtechniques.Wedrawonexpertsthroughout industry,
theregulatory
bodies,thelegalprofession
andacademia to ensurethatour
trainingpackages
arebathhighquality andrelevant.
8 A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
IV: 10 United Nations Environment Programme' Industryand Environment
Saving Our Planet: challenges and hopes [1992] Beyond the Limits: global collapse or a
M.K. Tolba (ExecutiveDirectorof UNEP). sustainable future? [1992]D.H. Meadows;
ISBN 0412473704. D.L. Meadows;J. Randers.ISBN 1 85383131 X.
This book analyses the changes that have Using World 3, a computer mode l, to project
occurred in the environment in the past two the future, and by varying the basic global policy
decades. It foc uses not only on the state of the assumptions,a range of possible outcomes is
environment, but also on the interactions between described. It is shown that a sustainable society is
development activities and the environment. It technically and economically feasible, if growth
highlights the ~ain responsessince 1972 to ifmaterial consumption and population are .,.,
protect the envlronment. ceased down and there is an increase in the }
Published by: efficiency of our use of materials and energy.
Chapman & Hall, 2-6 Boundary Row, Published by:
London SEI 8HN, UK. Earthscan Publications Ltd.,
Environmental Data Report 1993.1994[1993] 120 Pentonville Road, London N l 9JN, UK.
United NationsEnvironmentProgramme. Changing Course: a global business perspective
ISBN0631 19043O. on development and the environment [1992]
This report is updated biennially and provides S. Schmidheiny.ISBN 0 262 691531.
the best available data and information on a wide This book provides an analysis ofhow the
range of environmental topics, including business community can adapt and contribute to
pollution, health, natural resources, population the crucial goal of sustainable development,
and settlements, energy, wastes and disasters. combining the objectives of environmental
Published by: protection and economic growth.
Blackwell Publishers, 108 Cowley Road, Published by:
Oxford OX4 l JF, UK. MassachusettsInstitute of Technology (MIT)
Chemical Pollution: a global overview [1992] Press,Cambridge, Massachusetts 02142, USA.
United NationsEnvironmentProgramme. Blueprint for Green Management:creating your
This book
pollution overviews
around the origins
the world, causedand impacts of
by selected company's own0environ
G. Winter.ISBN mental
07 709015 2. action plan [1995] ,-..
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
---
1V:11
8 A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
IV: 12 United Nations Environment Programme' Industry and Environment
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Training Malerial
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~--- ---
v:3
8 5 Training Malerial
5.1 Introduction
The work exercises in this part require a not confronted with unexpected problems or
considerable amount oftime and a thorough questions from the participants!
study of the background readings in advance. Most exercises are based on interactive
Further notes and some model answersare processes,involving groupwork problem solving.
provided to help the trainer facilitate the However, the exercises can also be done
workshop. individually. Trainers are encouraged to adapt the
The exercises are not suitable for handing out given exercisesto suit the target audiences,and
as they are presented. It is left to trainers to adapt to develop additional exercises to extend the
the exercises to their particular needs. The trainer leaming experience.
should first try to do the exercise, so that they are Further ideas for activities and uses of the
material in this package are given below.
-'","","""""c. ""'""",""",.1,,;lw,"'," ~
v:4 United Nations EnvironmentProgramme. Industry
andEnvironment
"-
52 Some ide as for training ac.livities )
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers ~
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C
",.; ,,~..
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5.2.5 Slags
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A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
5.3.1 Introduction
Newspapers Universitylibrary
Internationalorganisations Publiclibrary )/
CD-ROM Patentoffice
Interviews Wholesalers
Consumerorganisations (International)databases
Other: ServiceSector:
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers --"
8
Table 5.1 Constituents of Table 52 Chemical additives to
used lead-acid batteries lead-acid batteries
Corn onent Per CentWei ht (typically in Canadian and US batteries)
Metalliclead 17 Additive Concentration %
Lead sul hate 50 Cadmium 0.1 -0.14
Plastic 5 Antimon 2.5 -7.5
Acid 24 Arsenic 0.15
Residuals* 4 Tin 0.1 -0.5
8 ;:::.1:
A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
è"
5A Work exercises )
..'
./ D ""
~ /
Polypropylene
.automobile
hortiCUlture parts
~ Proof
Storage Secondary
'::::~ Smelter
User
"
-ii,~, /
neutraiized
Acid
recovered
treated,
or
BatteryProducers
Aillead-acid batteries have to be collected and country in the world. ln some countries, a
recycled in order to minimize the environmental recycling rate of more than 100% bas been
and healthrisks of inappropriate disposai. Also, achieved, but this is a result of a delay in battery
aIl environmental and health risks should be collection in the previous year.
minimized during the collection of lead-acid ln the following exercise, you are asked to clarify
batteries, and storage of used lead-acid batteries why a yearly recycling percentage for lead-acid
should be avoided as much as possible. As is batteries of 100% bas not been achieved in any
clear from the background reading in Part /II, country, and what environmental and health risks
this ideal situation has not been realized by any arise in the lead-acid battery recycling network.
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers '"
~
'êêêêê1 ~ batteryto the retaller,collector,or drop-off depot?
~I
êê"\êiê'CC
êêê,
ê
,
1 1
(h) Whatenvironmentalthreatsand healthrisks occurwhenthe consumerkeeps
the batteries"in-house" for a long time?
1 1
Somesuggestions
for answersto this questionare onpage v:40
1 1
(h) What environmentalthreatsand healthrisks occurwhenthe batteriesare stored
commerciallyfor a long time?
1 1
Somesuggestions
for answersto this questionare onpage v:40
8 1 1
1 1
Somesuggestions
for answersto this questionare onpage v:40
Introduction )
Environmental and Technological Issues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers --'
8 Process description
4 (a) Give three reasons why the sulphuric acid is separated from the lead containing ")
fraction:
Somesuggestions
for answersto this questionare on page V:40
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaok for Trainers ~
8 CM 5 Refer 10 Table 5.3. ln this exercise you are asked to calculate a mass balance for
6 (a) What dangers are the workers exposed to during the battery wrecking
operations in developing countries? (Seea/so background materia/ and Materia/s
Safety Data Sheets):
8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
v:14 United Nations Environment Programme' Industryand Environment
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers ./
8 For meeting the requirements on clean number of ladIes needed for one lead and/or slag
workplaces, it was stipulated from the beginning tapping operation. The ladIes are kept under the
of the project that feeding and tapping are carried hood with the suction system permanently
out with the suction system continuously operating until the melt surface has solidified and
operating. For that reason, both ends of the short smokeless transportation is possible. The charge
rotary fumaces have been equipped with hoods. is taken to a vibrating feeder with the aid of an
These hoods (at both the tapping and the feeding enclosed chain conveyor. The feeder bas also
end) have been designed in such a manner that been integrated in the hood, thus completely
they offer enough space to accommodate the avoiding dust formation during fumace feeding.
7 Due to the use of oxy-fuel bumers, the generation of lead in dust bas decreased
considerably. Exactly how much has lead in dust been reduced, per tonne of
battery scrap?
8 Calculate the fractions of the constituents and the total weight of each load in the
two short rotary fumaces, based on an annual capacity of the facility of 1 million
used lead-acid batteries. Assume the fumaces are in operation for five days a week,
42 weeks a year. The fumaces are charged five times per day:
""
v:16 United Nations Environment Programme. Industry
andEnvironment
"
Due to new environmentalregulationswhich will be enforcedin the near future,the recycling plant will ê)
haveto separateail componentsof the batteries.Therefore,the wreckingprocesshasto be changed.
,0
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers
...
1 v:17
8 Conclusions
T he plant describedabovehasbeendesigned
to produceapproximately60%of quality
Two endproductsaredischargedfrom the
plant: marketleadand slag,originatingfrom the
99.95%purity andthe balanceof approximately shortrotaryfumacewhich is takento a dump.
40% of hard lead,basedon the intendedannual This slagis the only lossandwasteproduct
quantityof feed materialof one million lead-acid accumulatingin the plant.
batteries.An overall recoveryof 97.2%will be Apart from the measuresdescribedabove,
obtained.Any intennediateproductaccumulating severalothertechnicaland organizationalactions
in the plant, suchasflue dustsanddrosses,are havebeenimplementedfor ensuringas cleana
recycled.This is alsotrue of service-andprocess workplaceaspossible.The most importantof
water. Chlorine,ifany, originatingfrom PVC is theseadditionalmeasuresare:
precipitatedwith leadflue dustandtransfonned .Ali walls andceilingsof any plant sectionare
into a rotary fumaceslag in specialflue dust smoothonthe inside;
campaigns.
8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Rêêycllng
1 1
Suggested
answersto this questionare on page v:41
1 1
Suggested
answersto this questionare on page v:42
8
Ideasfor answering this question are on page v:42
8 A Workbook
for Trainers
: Environmentaland Technologicallssues relatedto Lead-Acid Battery
"
" 15 Fugitive emissions arise during various batch and transfer operations. ln addition, )
iî. waste treatment procedures also play a significant raIe. Accordingly, emissions
{î.~ from a process can vary considerably, depending on the degree of'good
fl;\j housekeeping practice', supervision and contraI exercised at a plant.
Suggestions
for answersto this questionare on page v:43
16 How should the design of the batteries be changed in order to reduce the
environmental impacts during the recycling process? Keep in mind that the
performance of the battery must not be reduced:
Suggestions
for answersto this questionare on page v:43
17 8ased on the lead recuperation rate at the refinery, how many batteries can be
produced only using lead which is produced by this secondary lead smelter?
Assume that new batteries contain IOkg of lead.
Suggestions
for answersto this questionare on page v:43
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers ./
* A fabric filter is considered an integral part of the lead oxide mill, ifany.
8
A Warkbaakfor Trainers: Environmental and Technologicallssues related to Lead-Acid Battery Recycling
" ""'~.".,'""."'."...
v:22 United Nations Environment Programme' Industry and Environment
Figure5.3Overallplantlayout
--
~ ~- =*=~.oDt-;;;;;;:
r --
'--j
Battery Wrecking :
Storage i
Source:
A Casting Storage
KHD
HUMBOLDT .
WEDAO Smelting Reflning
Figure5.4Wrecking
section
,---, 1
1 1 1 1
1
1 l' 1
1 1 1 l
,
~
1
~~
1
II
1
1
1
" 1 Spikecrusher
.a
'
1
.1 .
~ ""p ( ~ l' 1 1 2 Acldseparator
, -~. ~~~: : 1 3 Rotaryshear
: ::: 4 Neutralisation
tankand
1 1 1 1 ~ polypropyienedischarge
1 1 1 l ' ,
-
1 1 " 1 5 Thickener
L Y '1 : 6 StorageforieadfractJon
, , 1 1
1 1 1 1
1l 1'1 1
~
1
1
~
1 1 1 1--' --1-'
1 "' 1 1
1
1
1
1
1 1
--.
III 4 1 1
1 1
1 1 1 : 1_- r 1:
1 IL:-.J 1 -1
1 Ip- 1 ' 1
1 1 1 1
1 1 1 1 1
1 1 1 1
l' : 1 1
1 1 PI' 1
1 1 ~ l , Y
1 L___' L T 1
l '-@-! L 1
: @@ : A
1 L _1 1 Source: ~
1
1
1 1
1 K HO
1 1 HUMBOLDT
~ ~ WEDAO
8 sourcA
KHD
HUMBDLDT
-WEDAG
source:! .,
KHD 1
HUMBOLDT l'
_WEDAG "
"
8 A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
')"
Figure5.7MaterialSafetyDataSheetfor lead(inorganic)
.Eyes
.Ingestion Headache,nausea, Do noteat,drink,or smoke Rinsemouth, inducevomiting
sorethroat, duringwork. (onlyin consc;ouspersans/)
abdominalspasm. andreferfor medicalattention
Additionallnformation )
l SEEIMPORTANT
INFORMATION
ONBACK 1
continued...
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers /
"- ..."~.'c-
li9Tiifillï v:25
8
Important data Physical State Appearance: Inhalation Risk:
Bluishwhite or silvery greysolidin various Evaporationat 20'C is negligible:a
forms. harmfulconcentrationof airborneparticies
Chemical Dangers: Gan,however,be reachedquickly.
The substancedecomposeson heating, Effects of Long-Term or Repeated
producingtoxic fumes.The substanceis a Exposure:
strongreducingagent. The substancemayhave effectson the
Occupational Exposure Limits: nervoussystemand kidneys..This
substancemaycause anaemlaand cold.
TLV ppm 0.1Smg/m3 (as TWA)(ACGIH Mayimpairmalefertility. Maycause
1989).PDK (as aerosol)0.007mg/m3 retardeddevelopmentof the new-born.
0.01mg/m3C (USSR1988). Dangerof cumulativeeffects. Effectsmay
Routes of Exposure: be delayed.
The substanceGanbe absorbedinto the
body by inhalationand by ingestion.
Physical Boilingpoint 1740'C
8 properties Meltingpoint 327'C
Relativedensity(water= 1) 11.3
Solubility
in water ,..none
Vapourpressure, Paat2S'C <0.1
Environmental Thissubstancemaybe hazardousto the environment.Specialattentionshouldbe
data givento air pollution.ln the food chain importantto humans,bioaccumulationtakes -
place specificallyin shellfish.
Notes Explosivelimitsare unknownin literature.Dependingon the degreeof exposure
periodicmedicalexaminationis indicated.Do NaT take workingclotheshome.
Referalso to Cardsfor specificlead compoundse.g. Leadchromate(ICSC# 0003),
Lead (II) Oxide(ICSC# 0288).
Additional
information
1 LEGALNOTICENeitherthe CECnor the IPCSnor anypersonactingon behalfof the CEGor the IPCS is
responsiblefor the use which mightbe made of thisinformation.
8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
"~."'"'..
v:26 United Nations Environment Programme. Industryand Environment
"
Figure5.8MaterialSafetyDataSheetfor lead(II)oxide
L. Additionallnformation 1
1 SEEIMPORTANT
INFORMATION
ONBACK 1
continued
...
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
8
Important data Physical State Appearance: Inhalation Risk:
Red to yellow-redcrystals. Evaporationat20'C is negligible:a
Chemical Dangers: harmfulconcentrationof airborneparticles
can, however,be reachedquicklyif
The su~stanc~decomposeson heating, powdered.
produclngtOXIC fumes(see ICSC#0052).
Reactsviolentlywith sodiumand Effects of Long-Term or Repeated
aluminium. Exposure:
Occupational Exposure Limits: The substancemayhave effectson
3 haemosynthesis, resultingin anaemia.
TLV (as Pb)0.15mg/m (as TWA)(ACGIH Disturbanceofthe central and peripheral
1988-1989). nervoussystemand damageto the
Routes of Exposure: kidneysmayoccur. Mayimpairmale
The substancecan be absorbedinto the fertility.Thiscompoundmaydisturbthe
body by inhalationand by ingestion. developmentof the central nervous
systemof the newborn.
Physical Meltingpoint , 888'C
properties . (water_ 1)
RI'e atlvedenslty
8 9.5
Solubility
in water """""""""'" none
Environmental
data
Additional
information
LEGALNOTICENeitherthe CEGnor the IPCSnor anypersanactingon behalfof the CEGor the IPCS is
responsiblefor the use which mightbe made of thisinformation.
Thiscard containsthe collectiveviews ofthe IPCSPeer ReviewCommitteeand may not reflectin ail casesail
the detailedrequirementsincludedin nationallegislationon the subject.
The user should veritycomplianceofthe cardswith the relevantlegislationin thecountryof use.
8 :
A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
~ """'" ""'"",..,
v:28 United Nations Environment Programme. IndustryandEnvironment
Figure5.9MaterialSafetyDataSheetfor sulphuric
acid
1 Additionallnformation 1
continued...
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
~~~.".,,"C"~~
fltl1l1; v:29
8
Important data Physical State Appearance: Inhalation Risk:
Colourless,
oily,hygroscopic
liquidwithno Evaporation
at20'C isnegligible:
a harmful
odour. concentration
ofairbomeparticles can,
Chemical Dangers: however,
bereachedquicklybyspraying.
Oncombustion,
formstoxicfumes(sulphur Effects of Short Term Exposure:
oxides).Uponheating,toxicfumesareformed. The substanceis very corrosiveto the
T.hesubst~nce is a str?ngoxidanta~dreacts eyes,the skin and the respiratorytract.
vlolen~ly
wllhcombustible .andreduclng.. Corrosiveon ingestionas weil. Inhalation
materlal.s.
Thesu.bstance ISa s~rongacld-II of an aerosolof thissubstancemaycause
reactsvlolentlywllhbases~ndIScorrosive to lungoedema(see Notes).
mostcommonmetals,formlnga flammable
gas(hydrogen: seeICSC#OOO1). Reacts Effects of Long.Term or Repeated
violently
withwaterandorganicmaterials with Exposure:
evolutionofheat.
Lungsmaybe affectedby repeatedor
Occupational Exposure Limits: prolongedexposureto an aerosolof this
TLV 1mg/m3(as TWA),3mg/m3(as STEL) substance.Risk of tooth erosionupon
(ACGIH1988-1989). repeatedor prolongedexposureto an
8 R t fE
ou es 0 xposure:
aerosolof thissubstance.
LEGALNOTICENeitherthe CEGnor the IPCSnor anypersanactingon behalfof the CEGor the IPCS is
responsiblefor theuse which mightbe made of thisinformation.
This Gardcontainsthe collectiveviewsof the IPCSPeer ReviewCommitteeand may not reflectin ail casesail
the detailedrequirementsincludedin nationallegislationon the subject.
The user should veritycomplianceof the cardswith the relevantlegislationin the countryof use.
8 A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
.-,ill"' cc"""",,,"',,"c,",.'c
v:30 United Nations Environment Programme' Industry
andEnvironment
i~.1 ~~~~.J~~~~ll!~'J~
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
""'""--
r~.i v:31
8 r:.1~~I~~~::l'L=I~ill~
R ead the background
opportunities.
paper below, on Analytical tools for identifying
This paper is taken from the United Nations lndustrial
Cleaner Production
Development Organization
(UNIDO) Training Course: Ecologically Sustainable Indus trial Development.
Divide the participants in two groups (depending on the number of participants you can divide the
participants into groups of 2, 4, or 8).
Group 1 Ensure that every phase from production or extraction ofPVCs (and its raw materials), lead,
sulphuric acid (and their raw materials), polypropylene (and its raw materials), and the production of
the other constituents is visible in the drawing.
Group 2 Design the lire cycle of lead. Ensure that every phase, from mining to disposaI, is visible in
the drawing. Name the different products in which lead is used, but don't describe the other resources
needed to make the product, e.g. when describing the use of lead in gasoline, don't include oil
refining in the drawing. Remember that lead is also used as a component of other chemical
substances, e.g. in pesticides, or ilS oxides.
8
Use the background materials in the attachments and those provided by the trainer to understand the lire
cycle, and use the data in these documents to design your lire cycle oflead. Use Figure 5.10 as an
example ofhow a drawing of the lire cycle could look.
emissions
8
aste Managemen
\. .( wastes
~ '/
8 ::'c"jj!!:
A Workbook for Trainers: Environmental and Technologicallssues related to Lead-Acid Battery Recycling
"
After drawing the life cycle, prepare a presentation, explaining the life cycle of the chosen subject. After )
the presentation, a plenary discussion could be initiated, raising some of the following questions:
.What information is missing from the drawn life cycle in order to be able to decide whether recycling
.How tan life cycle analysis be useful for deciding on the benefits of recycling a product?
.How tan or should 'environmental costs' be incorporated in calculating the true costs of a product?
Recommended literature
Life Cycle Assessment: what it is and how to do Geneva: World Health Organization,
it [1996] Paris, France: United Nations International Agency for Research on Cancer.
Environment Programme, Industry and IRPTC Data Profile on: Lead [1990] Geneva:
Metals (Cu, Ni, Pb, Zn, Au) Ore Mining: A Programme (IRPTC/UNEP).
Technical Guide [1991] Technical Report Risk Reduction Monograph No. 1: Lead
Seri es No. 5. Paris, France: United Nations Background and National Experience with
carcinogenic risk of chemicals to humons: World Directory: Secondary Lead Plants [1994]
Some Metallic Compounds [1980] Volume 23. Fifth edition. London: International Zinc and
r;.'[{;~l:03I~lli~:;il[\:-~ Li::.]LJii1::; ~~:'::;il03~-:~:; :.:., Li~:; ~i!ir;] ~~ :03[1::;:.:ii 11[:;~_l~cr.:..':03!r;1i~:-JLU:; I:;~'J ~Ji.iir;: il::;:-Jr;::
analyzed. The necessary data collection and interpretation is contingent on proper understanding
the removal of raw materials and energy sources or package from the raw materials and delivers it
from the earth, such as the harvesting oftrees or to consumers. Three substages or steps are
the extraction of crude oil. Transport of the raw involved in this transformation: materials
materials from the point of acquisition to the manufacture, product fabrication, and
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers
The following general issues apply across ail four use of fuels in transport vehicles or process
lire-cycle stages: operations.
Energy and transportation Wastemanagementpractices
Process and transportation energy requirements Depending on the nature of the product, a
are determined for each stage of a product's lire variety ofwaste managementalternatives may be
cycle. Some products are made from raw considered: landfilling, incineration, recycling,
materials such as crude oïl, which are also used and composting.
as sources of fuel. Allocation of waste or energy
Use ofthese raw materials as inputs to products among primary and co-products
8 represents a decision to forego their fuel value.
The energy value of such raw materials that are
Some processesin a product's lire cycle may
produce more than one product. ln this event, ail
incorporated into products typically is included as energy and resourcesentering a particular process
part of the energy requirements in an inventory and ail wastes resulting from it are allocated
analysis. Energy required to acquire and process among the product and co-products. Allocation is
the fuels burned for process and transportation most commonly based on the mass ratios of the
use is also included. products, but there are exceptions to this.
Environmental waste aspects Summing the results of each stage
Three categories of environmental wastes are To calculate the total results for the entire lire
generated from each stage of a product's lire cycle of a particular product, the energy
cycle: atmospheric emissions, water-borne requirements and certain emission values for each
wastes, and solid wastes. stage of the product's lire cycle can be summed.
These environmental wastes are generatedby For example, energy requirements for each stage
both the actual manufacturing processesand the are converted from fuel units to million British
8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
v:34 United Nations Environment Programme. Industryand Environment
,
Thennal Units (BTUs) or megajoules and basis. Claims for confidentiality should be made ,1
summed to fmd the total energy requirements. only when it is reasonableto expect that release
Solid wastes may be summed in pounds or of the infonnation would darnage the supplier's
converted to volume and summed. The current, competitive position. Even then, the data inputs
preferred practice is to presentthe individual to an extemal use are legitimately expected to be
environmental releases into each of the independently verified.
environmental media on a pollutant-by-pollutant A peer review process leading to agreed-upon
basis. Where such specificity in an extemal study reporting is one possible mechanism for dealing
would reveal confidential business infonnation, with this issue. Other approaches for independent
exceptions should be made on a case-by-case verification are possible.
Table5.5Recyclable/non-recyclable
applications
for lead
Rec clable Non-rec clable
Batteries Gasolineadditives :i
Roofin Iflashin s Glass
Pi es Plasticsstabilizers
Gable sheaths Shot-ammunition
Radiationshieldin Paint i ments
Windowtrames Solders
Yacht keels Geramic lazes
Wheelwei hts
Table5.6Recovery
ofleadproducts
Product Product Recove
Batteries:
auto~obile -90 3-4 }
traction -100 4-6
stationa -100 u ta 10
Sheet 90-95 50-100
Pi e 70-80 50-100
Gablesheathin 50 40
.,..,
HIa v:35
8 cC;:
A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
v:36 United Nations Environment Programme' IndustryandEnvironment
totalreportedconsumptionby country
ThousandMetricTonnes
1988 1989 1990 1991 1992 1993 %change
1992.3
Australia 49.3 51.7 46.0 42.6 43.1 51.2 18.8
Austria 61.0 61.0 65.5 66.0 66.0 62.0 -6.1
Sel ium 66.1 62.0 67.7 63.5 64.5 66.0 2.3
Srazil 95.5 100.3 75.0 66.0 69.0 74.0 7.2
Canada 88.0 87.7 71.5 79.6 91.7 89.1 -2.8
.12.1 13.2 13.4 12.2 7.0 4.0 -42.9
238.2 265.4 263.2 266.3 259.4 240.2 -7.4
336.9 366.2 375.3 401.0 397.5 362.4 -8.8
51.1 52.9 51.8 53.6 40.2 33.9 -15.7
252.0 261.0 259.0 259.0 247.0 234.0 -5.3
406.5 405.7 416.4 422.2 401.3 371.2 -7.5 )
blic of 146.0 155.0 149.0 164.0 164.0 178.0 8.5
Mexico 77.1 85.7 66.8 79.7 92.5 84.0 -9.2
Netherlands 58.4 58.5 62.0 59.0 52.0 48.0 -7.7
NewZealand 7.6 10.0 8.0 5.1 5.1 6.7 31.4
***Scandinavia 58.4 41.8 36.3 33.0 33.0 41.0 24.2
SouthAfrica 56.1 62.9 65.9 53.9 53.9 52.7 -2.2
****SouthEastAsia 171.4 172.0 185.0 237.0 237.0 253.0 6.8
Sain 110.9 110.0 126.7 105.0 105.0 104.0 -1.0
iz 10.7 7.9 8.7 7.6 7.6 7.5 -1.3
dom 339.5 336.4 334.0 302.3 302.3 298.0 -1.2
s 1245.2 1277.6 1275.2 1240.7 1240.7 1357.1 9.4
Total 3924.8 4044.9 4022.4 4027.7 3979.8 4018.8 1.0
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers -'
Part 5 .Training Materia!
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8
Table5.9Summary
tables:lead
principal uses
LEADCONSUMPTION:THOUSANDMETRICTONNES
1988 1989 1990 1991 1992 1993 % change
1992.93
Batteries 2394.3 2492.3 2541.3 2557.8 2565.6 2661.7 3.7
Gablesheathinq 183.2 196.0 182.1 169.9 152.5 143.5 -5.9
Rolledandextruded 312.0 311.8 309.6 284.9 273.2 265.4 -2.9
fJroducts
Shot-ammunition 93.8 98.8 101.3 108.8 113.2 115.4 1.9
Alloys 147.1 141.8 134.4 133.8 139.0 137.8 -0.9
Pigments and other 526.6 557.0 517.0 542.9 530.6 488.9 -7.9
comfJounds
Gasoline additives 103.0 98.2 86.9 74.0 58.1 54.3 -6.5
8 Miscellaneous 164.8 149.0 149.8 155.6 147.6 151.8 2.8
Total- 3924.8 4044.9 4022.4 4027.7 3979.8 4018.8 1.0
PERGENTAGES
OF TOTALGONSUMPTION
1988 1989 1990 1991 1992 1993
Batteries 61.0 61.6 63.2 64.0 64.5 66.2
Gablesheathing 4.7 4.8 4.5 4.2 3.8 3.6
Rolled and extruded 7.9 7.7 7.7 7.1 6.9 6.6
fJroducts
Shot-ammunition 2.4 2.5 2.5 2.7 2.8 2.9
Alloys 3.7 3.5 3.3 3.3 3.5 3.4
Pigments and other 13.4 13.8 12.9 13.5 13.3 12.2
comfJounds
Gasoline additives 2.6 2.4 2.2 2.1.8 1.5 1.4
Miscellaneous 4.2 3.7 3.7 3.9 3.7 3.8
Total- 100.0 100.0 100.0 100.5 100.0 100.0
8 * Countries included: Australia, Austria, Belgium, Brazil, Canada, Finland, France,Germany, lndia,
ltaly, Japan,Republic of Korea, Mexico, Netherlands, New Zealand, Scandinavia, South Africa, South
East Asia, Spain, Switzerland, United Kingdom, United States.
8 :
A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
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v:38 United Nations Environment Programme' Industryand Environment
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5.4.5 Comparison of lead-acid battery recycling technologies )
")
There are various types oflead-acid battery recycling facilities, ail using a range of technologies and
techniques. As a consequence,the end products and their quality differ depending on the facility where
the lead-acid batteries are recycled. End products may vary from scrap and secondary lead, to reusab.1e
polypropylene, detergents,refined lead, etc.
The recycling facilities mainly differ from each ailier in two respects:
This exercise consists oftwo assignments. The first assignmentasks you to make an environmental
evaluation ofseveral types ofwrecking operations. The second assignment concems the selection of the
most environmentally friendly smelter type. You are asked to choose one of the assignments.
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A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
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Question 6 1 SeeInternationalChemicalSafetyCards,underacutehazards/symptoms,
prevention,
andeffectsof long term or repeatedexposure.
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
8 Question 7 Fuel consumption draps from 90kg to 40kg peTtonne of scrap. Waste gas draps from
12m3to 3.2m3/kg fuel. Maximal dust content in cleaned gas is 2.5mgiNm3. Dust
content draps from 50% to 35%.
Reduction of lead in dust peTtonne scrap can be calculated as follows:
(1- (40 kg * 3.2m3/kg * 2.5mg/Nm3 * 0.35)/(90kg * 12m3/kg * 2.5mg/Nm3 * 0.5» * 100%
= 91.7%
Question 8 During wrecking operations, 95% of the sulphuric acid is removed, and lime is added
to neutralize the residual acid in a ratio of 1.2:1 on a weight basis. Total weight after
wrecking section:
1 million batteries/year * 17.2kg/battery 17,200 tonnes of batteries/year
Removed sulphuric acid = 0.24 * 17,200 * 0.95 3921.6 tonnes
Added lime = 0.05 * 17200 * 1.2 " 1032 tonnes
Total battery scrap after wrecking operations is:
17200 -3 921.6 + 1 032 14 310.4 tonnes
Input for smelting section consists of 85% from wrecking section, 10% dust and
8 recycling products, and 5% reagents. Total input in rotary fumace is 16 835.8 tonnes.
Therefore, the average load of one rotary fumace is:
16835.8/(5 * 5 * 42 * 2) = 8 tonnes
Question 9 You may want to use the example of the secondary lead smelter given in 3.4.4 Low
waste technology for reprocessing battery scrap in Part 3: Technical Background
Papers. One of the exercises in Part 5 focuses on the different wrecking techniques.
You may want to do that exercise flrst.
Question 10 (a) The fraction oflead in the rotary fumace will increase.Based on an average
capacity of each load of 8 tonnes,the capacity of the plant will increase.
(h) The energy consumption may be lower becausethe plastics are not used as an
energy source anymore.
Question 11 (a) The risks oftransportation (accidents, but also spilling of lead-acid from trucks
passing through urban areas). Wastewatercontaining lead, sulphuric acid and other
heavy metals may be discharged into the surface water with inappropriate treatment.
8 Lead emissions during smelting, refining, and ingotting -either through air, water,
or crops (see transparency on exposure pathways in Section 3.3). Due to sprinkling
of the site to prevent the formation of lead dust, the soil may become contaminated
with lead.
(h) During malfunction/accidents, the afterbumer and emission contrai equipment may
not be able to retain pollutants like sulphuric acid fumes, lead, and SO3,and dioxins
may be formed due to incomplete buming.
Students were asked to investigate the risks associatedwith each of the
constituents of the lead"acid battery as part ofPreliminary Exercise 3. The
consequencesof emissions from secondary lead smelters for human health are also
summarized in 3.2.1 Environmental agency closes down company alter finding lead
in human blood, cows' meat; 3.2.2 Potential environmental and occupational hazard
from lead; and 3.2.3 Mechanismsfor risk reduction oflead in the European
Community, in Part 3: Technical Background Papers.
8 ;;
A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
v:42 United Nations Environment Programme' IndustryandEnvironment
,
Question 12 (a) Slags can be used as construction material- for road foundations, etc. )
(h) The major drawback may be that the heavy metals are not immobilized enough and
start leaching, causing soil pollution, or leading to health problems in the buildings
where they are used.
Question 13 There are several possibilities, including using it to preheatthe scrap before it enters
the smelter; it can also be used to generate energy/electricity, or for heating
surrounding buildings.
Question 14 The concentration in the air should always be below 0.05gim3. That means that the
ventilation system should be able to remove asmuch lead dustltime unit as is being
generated by the two rotary fumaces. The ventilation system should be able to reach a
steady state with a lead concentration in the air of 0.05 (gim3).
QI = flow of dust from smelter (lm3/h).
Q2 = flow being ventilated (unknown/h).
Q3 = flow without lead going into the hall = Q2-QI.
CI = concentration lead dust in QI = 60 (gram/m3).
CI = concentration lead dust in the hall (gim3).
C3 = 0 (gim3).
V = volume of the hall = 3600m3.
t = time (h).
When time reaches infmity, CI should remain 0.05gim3.
The concentration at t = 0 is 0 (gim3).
This leads to the following equations:
dC
V-1- = QICO -Q2Ct +Q3C3
dt
In(QICI -Q2Ct) --
-dt
-Q2 V
1 -tQ2
Ct = -(QI CI- exp(- + In(QICI)))
Q2 V
For t ~ 00,CI reaches 0.05 (g/m3). This leads to the following equation:
Ct = -9l CI
Q2
From this, it follows that the ventilation capacity Q2 = 1200m3/h.
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers
8
0 .
1
Appendices
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Appendices
"
l A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
",,-," """ 3
Appendices
8
Appendix 1
Supporting Documents for tbis Package
8 A Warkbaak for Tra;ners: Environmental and Technologicallssues related to Lead-Acid Battery Recycling
--~-,...'".
4 United Nations Environment Programme' Industry and Environment
"
Appendices
..." '"Co
5
Appendices
8
Appendix II
List 01Training Resource Packages
available Irom UNEPlE
8 A Workbook for Trainers: Environmental and Technologicallssues related to Lead-Acid Battery Recycling
-.,
Enquiries UNEP lE
Tour Mirabeau
39-43 quaiAndré Citroën
75739ParisCedex15
France
Tel 33 (1) 44 37 1450
Fax 33 (1) 44 37 1474
Email unepie@unep.fr
http://www.unepie.org/home.html
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers
Appendices
7
Appendices
8
Appendix III
About UNEPIndustrv and Environment
8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers
Appendices
i
8
Evaluation Form
Environmental and Technological Issues
related to Lead-Acid Battery Recycling
A s part of the continuingreviewofthis trainerspackage,wewould appreciateyour cooperationin
answeringthe following questions.Pleaseretumthe completedevaluationform to:
UNEF lE, Tour Mirabeau, 39-43quai André Citroën, 75739Paris Cedex15, France
Fax 33 (1) 443714 74.
1 Do you have any suggestions for improvement of the trainers package?How couId we
improve its readability, contents, practical use, and so on?
2 How was the package useful in preparing your own training activity?
8
3 Did the background information and the transparencyset in Part 3 provide you with
enough information? What was missing?
continued
...