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UNEP IndustryandEnvironment

Environmental and
Technologicallssues
related to
Lead-Acid
BaDen Recvcling

l -A Workbook lor TraiDers

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Environmental and
Technologicallssues
relaled 10
8 Lead-Acid Ballerv
Recvcling
1 A Workbook for Trainers 1

First Edition .April 1996

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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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~ Industryand Environmental
andTechnologicallssues .,
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~~~..~..é'l Environmental lead-Acld Banerv Recvcllng
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.

ACknOWled~emen~s " .')


The first version of thls tramers workbook was prepared m
1994 by J.W. Scheijgrond and F. Balkau forUNEP lE.
It was subsequently trialled in workshops and courses in
several places, leading to subsequentrevisions to produce
this current document.

UNEPwould like to thankthe many individualsand


organizationswho contributedideasand materials,or who
assistedin reviewsandredrafting.Particularthanksgo to
Mr H. Ahmadzai,Mr R. Boehnke,Mr J. Delcambre,Mr J. Hay,
Mr M. Hyman,Mr M. Ichimura.the InternationalLeadZinc
OrganizationInc., Metaleurop(Mr P. Fossi,Mr P. David,and
Ms E. Perrier),and Mr A. Tay.

Copyright @UNEP 1996


Ali rightsreserved.No part ofthis publicationmaybe produced,storedin .
a retrieval systemor transmittedin anyform or anymeans:electronic,
electrostatic,magnetictape,mechanical,photocopying,recordingor .')
otherwise,without permissionin writing from the copyrightholder.

First edition April 1996


The designationsemployedandthe presentationof the materialin this
publicationdo not imply the expressionof anyopinion whatsoeveron the
part of the United NationsEnvironmentProgrammeconcemingthe legal
statusof any country,territory, city or areaor of ilS authorities,or
concemingdeiimitation of its frontiersor boundaries.Moreover,the
views expressed do not necessarilyrepresentthe decisionor the stated
policy of the UnitedNations EnvironmentProgramme,nor doesciting of
trade namesor commercialprocessesconstituteendorsement.

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

8 Part Il Organizing E~ective Training Activities


2.1 Introduction 11:3
2.2 Notes on interactive workshop organizatioll 11:4
2.3 Someideasfor moreeffectivecommunication II:5
2.4 Somepersonalsuggestionsfor effective.training II:6
2.5 Resource persons guide II:1
2.6 Suggestions for self study II:9

Part III Technical Background Papers


3.1 Introduction III:3
3.2 Introductory articles III:5
3.3 The recyclingschemeoflead-acidbatteries 111:11
3.4 Secondary lead smelting III:25
3.5 Transparencies , III:51

Part IV Information Sources


4.1 Introduction IV:3
4.2 Sources of information IV:3
8 4.3 Documentson lead~d lead-acidbatteriesrec:cling IV:5
4.4 Handbookson chemlcals,humansandthe envlronment IV:1
4.5 Audiovisuals , IV:8
4.6 Someusefulbackgrounddocumentson the environment IV: 10

Part V Training Material


5.1 Introduction V:3
5.2 Some ideas for training activities V:4
5.3 Some ideas for preliminary exercises """"""""""""""'."""""""""""' V:6
5.4 Work exercises V:8
5.5 Answers to the work exercises V:40

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

T his is a train ers support


reference book.
package,
It does Dot give a
not a problem-solving.
by a tutor who is a recognized
Such work needs to be guided
expert in the field.
systematic, comprehensive overview This method allows the full complexity of real
(there is Dot enough room to do fuis); rather, it decision-making to be explored.
focuses on some selected aspects that are central Where calculations are required, they are more
to the subject. The structure of the document oriented towards throwing light on useful
allows further sections to be easily developed and approaches or management decisions than simply
added as additional modules. finding the 'correct' answer. Trainers are
The package is written for trainers to provide strongly urged DOt to see ibis package merely as
them with support material and ideas, rather than a set of arithmetic exercises.
8 as a study book for students. The average trainee ln some instances, answers are indicated. For
will only ever see a few pages or exercises many problems, the 'correct' answer depends on
reproduced from ibis document. the context of the question. It is here that a tutor
One of the purposes ofthis package is to provide or extemal resource expert is useful.
some case studies and situation scenarios that can Many trainers fmd this disturbing. They should
be used as a basis for interactive training and remember that real decision-making depends on
simulated decision-making. However, the the wider circumstances surrounding the
exercises only explore a small part of the potential problem, and that a numerical answer which is
of the case studies, and trainers are strongly politically or socially unacceptable, or
encouraged to develop further exercises or tasks. administratively unworkable (even though
The package is oriented at developing insights accurate), is DOt in effect 'correct'.
and decision-making skills. For teaching the The simulation ofreallife situations and
factual knowledge base of the subject, train ers are decision-making that is the basis ofthis package
referred to the reading lists in the bibliography. makes it most suitable for senior students and
Work exercises are predominantly based on trainees, and especially for professional training
interactive groupwork and a team approach to (or retraining) courses.

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

Howto stan a training activitv )


based on this workbook

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.

decision-making. 13 Consider how to fo/low up and reinforce


Il Commence the work sessions, preferably the learning experience by establishing
in small groups, and preferably guided by some ongoing projects, or periodic reunions.

)
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:

The shading shows your current position in the text.

)
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

e Cradle-to-grave The life cycle of a product,from


raw materialto final disposaI.
Dross By-productwhich is formedduring refining.
weights,e.g. mercury,chromium,cadmium,arsenic,
andlead.
Ingotting Solidifying of lead in molds afterrefining.
Chemicalcompoundsaddedduringrefining form Lead bu Ilion The liquid lead,still containing
drosses,which usuallyfloat on the moltensurface. impurities,which is formed in the smelter.
Apart from lead,drossescontainimpuritiessuchas Life cycle The combinationofprocessesneededby a
copper.nickel,andantimony. productto fulfil the functionspecifiedby the
Emission An emissionusuallyrefersto fugitive or functionalunit. Life cycle stagesinclude production,
wastedischargesfrom a process.Emissionsare useandprocessingafter disposai,includingthe
traditionallyassociatedwith atrnosphericdischarges. processingof the wastegeneratedin thesestages.
End-of-pipe treatment Treatingpollutantsatthe end Life cycle analysis A quantitativeassessment of the
of a process(by, for example,filters,catalystsand total environmentalimpactscausedby a particular
scrubbers)insteadof preventingtheir occurrence. processor product,from resourceconsumptionto
Environmental auditing The management tool contamination,from the cradleto the grave.
comprisinga systematic,documented, periodicand Mass/Material balance A preciseaccountof aIl the
objective evaluationof how weIl environmental inputsand outputsof a process,basedonthe lawof
organization,management
and equipmentare conservationof mass.

e "c "A WorkbookforTralners":Environmental and Technologicallssues related to Lead-Acid Battery Recyclmg

" 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

Environmentaland Technologicallssues related to Lead-AcidBattery Recycling : A Warkbaak


for Trainers

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Part 1
Introduction
i

( 1.1 This package 1:4

1.2 Contents of this package 1:5

( "," -
1:3

8
1 Introduction

M any teaching institutions and ln 1993, in responseto these findings, UNEP,


individual trainers have difficulty in WHO, and ILO jointly initiated the programme
following the rapid evolution of on Training Approaches for Environmental
environmental issues that are relevant to their Management in lndustry. The programme airns to
courses. enhancethe capacity of national institutions to
This is particularly true when teaching subjects offer local training on topics concerned with the
8 such as pollution and environmental manage- prevention of industrial pollution.
ment. And yet it is important that new graduates ln this context, trainers' packageshave been
have a good knowledge of issues in which they prepared on different areas of environmental
may eventually provide consulting services or management.These packagesare intended to
policy advice to governments and industry. help educators and trainers to develop their own
The fact that development and environment are workshops or curricula, or to integrate some of
interrelated means that it is more vital than ever the ideas and infonnation into aIready existing
that: teaching programmes.

.ail professionalshavea basicenvironmental It is important to keepin mind that


literacy that helpsthemto incorporate thesetraining resourcepackagesmerely
environmentalpriorities into their specialized pro videafirst orientation to the topic.
work,whatevertheir profession;
.specializedenvironmentalcoursesare relevant ln no waydoesthepackageconstitute
to today's environmentalagenda. a 'course' in its own right.

8 "'"'"'"'"'"'"'c""'AWorkbookfOr
Trainers
: Environmentaland Technologicallssues relatedto Lead-Acld Battery Recycllng
1:4 United Nations EnvironmentProgramme' Industry
andEnvironment

1.1 This package ')

T his packageis a workbookthatcomplements


the trainer's packageon 'C/eaner
balancedcurriculumin responseto the needsof
his/heraudience.Any missingelementsmay be
Production'. For bestresults,both shouldbe used found in one of the otherUNEP manuals,to be
together.ln manycases,it would be usefulto use convertedinto training formatbasedon the case
the C/eanerProductionmaterialasan studiesandscenarioincludedhere.
introductionto any curriculum-basedmaterialin Thus,the packageis Dotstatic.
fuis workbook. As feedbackis receivedfrom usersand
The workbookis balancedbetweencurriculum- technicalspecialists,the materialwill be
basedcontent(usefulfor technicians)anda more modified andenriched.
management systemsapproach(usefulfor Usersareencouragedto report on their
supervisorsandmanagers).ln practice,both will experiencesin usingfuis package,and to sendin
be needed,andthe traineris urgedto developa suggestionsfor improvements.

-.~)

T he packagefocuseson the environmental


aspectsof productrecycling. It usesbattery
how environmentalproblemsrelatedto recycling
canoccurandbe solved.
recyclingto illustratethat productrecyclingcan, This training resourcepackageconsidersthe
if precautionsare not taken,causeserious technologiesof recyclingthe variousconstituents
environmentaland healthproblems.The reasons of the lead-acidbattery.We referto these
why it hasbeenselectedfor this training resource technologiesas secondary/eadsme/ters.Health
packagearethat: and safety,pollution control,and environmental
.recycling of lead-acidbatteriesand leadscrap impactare integratedin fuis consideration.
basa historygoing backto the last century,and lt is during secondaryleadsmelting that the
is weIl understood. mostseriousenvironmentalproblemsoccur. The
.compared to otherrecycling loops,the backgroundpapersdiscussvarioussecondary
recyclingof lead-acidbatteriesis fairly simple leadsmeltingtechnologies,andthe exercisesin
and effective.ln manycountries,morethan Part 5 also focus mainly on thesetechnologies.
90% of alllead-acid batteriesarerecycled. ln the contextof fuis package.it is impossible
.although recycling is oftenregardedasbeing to includeaIl the informationon lead-acidbattery
automaticallyenvironmentallyfriendly,this is recyclingtechnologies.Due to increasing ;-
DOtalwayscrue.Lead-acidbatterysmelting pressureforcing (secondary)lead-smeltersto
confirmsthis. Smeltingandrefining of lead- comply with stringentenvironmentalstandards,
acid batteriesinvolve considerablerisks for many developments are going on in fuis field,
humansandthe environmentwhenno adequate andmany newtechnologiesare emerging.
pollution controlmeasuresareprovided. UNEP lE plansto publish in 1996/97a
However,simple disposaiof batteriesalso technicalreportthatgives a more comprehensive
posesseriousproblemsfor the environment. andsystematicoverview.The trainer may thus
Lead-acidbatteryrecycling functionsasa wantto updatethis packagefrom rime to time.
usefui role-modelfor recycling practicesin this Part 4 givessomeaddresses whereupdateson
training resourcepackage. the latesttechnologiescanbe found.
This role-modelfunction(and its associated The packageis suitablefor a wide range of
environmentalproblems)canbe usedas an audienceswho do not necessarilyneeda
exampleof how a recyclingschemeis setup, and technicalbackgroundin orderto be able to
understandthe suggestedreadingand undertake

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers

Part 1 .Introduction
",CcCC'"'"" t dccJ
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105
pilii::~' ~~1.'F

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

"' 12 Contents of tbis package


8
T his packageis conceivedprincipallyto help .supplementarytechnica/informationto support
trainerspreparea seminar,workshop,or somework exercises;
extendedcourse.It is not a courseperse. .work exercisesandquestions;
The packagecontains: .appendiceswith further informationabout
.suggestionsandhints for effectivetraining; UNEPand its programmes.
.a short backgroundtothe subject,drawnfrom Trainersareencouraged to extendthe package
otherexistingpublications; by addingtheir owncasestudiesand exercises,
.overhead transparenciesto introduceand andexpandingthe subjectcoverageinto new
illustratethe main ideas; topics.For example,trainers in environmental
.case studiesand situationreportsandscenarios healthmay wish to addsomemoduleson
drawn from actualexperience; occupationalsafetyand ecotoxicityby building
onthe chemicalinformationalreadypresentedo

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

-
11:1

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UNEP

Part 2
Organizing Enective
r Training Activities

2.1 Introduction Il:3

2.2 Notes on interactive workshop organization Il:4

<. 2.3 Some ideas for more effective communication Il:5

2.4 Some personal suggestions for effective training 11:6

2.5 Resource persons guide , Il:7

2.6 Suggestions for self study 11:9

"
Î
Il:3

8
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

""_L_.c C.'.-"-
Il:4 United Nations EnvironmentProgramme' IndustryandEnvironment

2.2 Notes on interactive workshop organization .)

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 "

environmentalproblems. .audiovisuals suchas videos,films, and slides


The UNEP/WHO workshopformat .field visits whereappropriate
incorporatesthe following elements: .personal actionplanningby participantsfor
.sending out pre-workshopreadingmaterial, follow-up activity.
with somesimpleexercises
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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.
~~---C=~_L

2.2.3 Organization ..~)


T he organization ofworking groupsessions
alsorequirescare.Groupsshould first meet
The foie ofresourceexpertsas advisorsis
crucial. Theyshouldhave sufficient experienceto
informally, electtheir own chairman,and thenact assistin aIl sessionsandprovide generaladvice
as a permanentteam in variousworkshop on ail subjectsin workshops,discussionor panel
sessions.Theyare guided,but not instructed,by sessions.Theyshouldnot, however,dominatethe
technicalexperts. workshops.
It is usefui to finish the workshopby preparing The five clayformatis ideal for covering ail
personalactionplans.Participantsshould develop theserequirements.If lessthanfive daysis taken,
and presenttheir proposaisfor what they can you canbe surethat importantissueswill be left
initiate immediatelyon their retumhome. Such out. If moretime is available,considerincluding
actionincludes: socialeventsandprivate studysessions,along
.what theycan achieveunassisted,and with moreextensiveprojectwork for the
.what elsetheycould achieveif someassistance students.
were available.

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers ).

Part 2 .Organizing Effective Training Activities


ritl~~'., Il:5

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 Before the learning event


Find out:
.how the leamers have been taught in the past
.the real needs and situation of the leamers
.whether the facilities are adequate for the envisaged training
.whether the training has the support of senior people
.how success will be measured.
Make a project plan for the organizers,giving details ofhow
the eventwill beorganized.Sendtheplan ta them.with details
ofthe keydatesand needs.

During the learning


.find out how relevant the topics are to the work situation of the
participants
.start with the familiar ail can -not a video of an ail
spill disaster
.communicate using topics, themes and issues inthe
local press
8 .store unanswered questions, and remember to answer
them before the end
.keep notes for participants to bullet-point fonnat
.ensure the participants keep notes for future reference -few
read essays, or even articles
.if you are working in a foreign language, at least translate the
siides.

After the learning event


.always communicate your thanks and best wishes
.infonn participants on follow-up study procedures, and how the
instructor can help to analyze the evaluations and infonn the
organizers of the results
.communicate to colleagues the results of the training and what
can be leamed from these results.

8
Issues related to Lead-Acid Battery Recycling
Il:6 United Nations Environment Programme' Industry and Environment

2A Some personal suggestions ')


for enective training

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

enthusiasm for the subject which is critical when teaching students.

To be an effective educator/teacher: The outstanding educatorlteacher:

.Provide an enjoyable learning situation that expands .Is fully acquainted with, and believes in, the

ail of the participants' network. educational merit of the subject matter.

.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

a lack of substance. individual students or groups of students.


Deborah Hanlon, Environmental Scientist Don Huisingh, Environmental Consultant and Professor at
Office of Environmental Engineering Erasmus University in Rotterdam
and Technology Demonstration, US EPA the Netherlands

To be efficient ('doing things right'), and The best educator/teacher:

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.

teaching them. .Has the ability to communicate. )


.Seek learner feedback, and measure learning .Will change the training programme and the ",

achieved with objective tests. approach if necessary.

.Set learning lime limits. .Is stililearning, and has recent applied experience of

.Seek conscious and unconscious leaming. the subject being taught.


.Seek learning that endures, based on .Has the ability to organise events and to manage

understanding and skills. things.


Bob Boland, Environmental Consultant, France Colin Sutherland, Educational Consultant, Franœ

;~
Environmental and Technologicallssues related to Lead.Acid Battery Recycling : A Workbook for Trainers )

Part 2 .Organizing Effective Training Activities

_..". .., ~
frIt Il:7

8 2.5 Resource persons guide

A sthis packagerelies heavilyon interactivegroupworksessions,


to be an effectiveresourceperson.
herearesomeguidelineson how

ln a casestudy-basedtraining approach,the resourcepersonservesmoreasa:


.facilitator of the group leaming process
.technical adviser as needed,
and a
.catalyst of leaming
rather than a:
.lecturer
.story-teller
or
.instructor.
8 Here aresomeguidelineson howto be an effectiveresourceperson.

1 Be surethat you havereadand understood and respectiveorganizations,etc.,which


thoroughly the participant'snotesbeforeyou shouldhavebeendoneon the first dayanyway.
meetyour group.There'snothinglike being .then askif the objectivesandpurposeof the
preparedandmore familiar with the casestudy exercise,whichhavebeenpreviouslydiscussed
scenariothanthe participantsare! in the plenarysession,areclearto them.
2 Before everygroupwork session,taketime
to visit your assignedmeetingroom and
Sampleobjectivesare:
-identify andunderstandthe optionsthat SMEs
checkthe: canemployin their pollution prevention
.seating arrangementsThereshouldbe a large program
enoughtable surroundedby enoughchairsfor -evaluate the feasibilityand suitabilityofthese
the participantsandyourself optionsin view oftechnical, environmental,
.equipment and suppliessuchas flipcharts, financial,organizational,and socialcriteria
flipchart papers,markeTpens,whitelblack andconstraints.
8 board,board eraser,maskingtape,transparency It will be usefulto know whetherthe majority
sheets,writing pads,ballpen/pencils,calculator, of the groupmembershave actuallyreadthe text
etc. provided,whichstatesthe backgroundandthe
.physical conditions of the room Thereshould problem.
be sufficient lighting,the room temperature Ifthey haveDot,thenyou will needto direct
shouldbe comfortable,noiseshouldbe as low themto focustheir attentionfirst on whatneeds

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

_c ~ ,""'
Il:8 United Nations Environment Programme' Industry
andEnvironment

without 'spoon-feeding'the participants. personsneedto be duly advisedon the ")


However,do Dotlectureor dominatethe group particularquestion.

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

"" ~
p~d:;I)ft Il:9

8 2.6 Suggestionsfor self studv

A lthOUgh this package was designed


to provide resources for trainers,
supplemented by further reading and additional
training materials listed in the Appendices, and
the potential for self-study should perhaps by site visits and discussions with
not be ignored. professionals.
The package does not constitute a complete The following approach is suggested for
course on cleaner production in leather tanning, individual study.
but can be seenas an introduction to be

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.

8 A Warkbaakfor Trainers: Environmental and Technologicallssues related to Lead-Acid Battery Recycllng

c-
Il:10 United Nations Environment Programme. Industry and Environment

.1

Environmentaland Technologicallssues relatedto Lead-Acid Battery Recycling: A Workbook


for Trainers )
Part 2 .Organizing Effective Training Activities

""L"
Transparencies

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polypropylene di 'charge

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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

Part 3 .Technica/ BackgroundPapers: Transparencies

.
)
111:85
Transparencies

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\1 \
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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

Conversion of Goverslag and dust pilesand $500 $9,700 3 weeks


Scrap Lead into cleansmeltingroom-reduces
Cast Panels: workerexposureto leadand
lead dust

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 .

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbookfo, T,aine,s


Part 3 .Techtlical Background Papers: Transparencies
~ "

IV:l

~
,, ~
p.c-c ~
~
~~~ Iff
UNEP

Part 4
Information Sources
(

4.1 Introduction Iv:3


4.2 Sources of information Iv:3
4.3 Documents on lead and lead-acid batteries recycling Iv:5

4.4 Handbooks on chemicals, humans and the environment Iv:7

, 4.5 Audiovisuals Iv:8


,
4.6 Some background documents on the environment Iv:l0

l c'
A Wor/{boo/{ for Trainers : Environmental and Technologicallssues related to Lead-AêidBatte~'Re~ycîi~g

~",,",,"~ '"'","""","c.".c.""""""c."""",~,."",~,,~.,,",,,,,j",,"_. ,"~...","~.""",..;"~",,;"" '.J,cc",


Iv:3

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
,

1V:4 United Nations Environment Programme. Industryand Environment

INFOTERRA 3404, US EPA, 401 M Street, "Spravochnik: ekologicheskiye }


,;!
S.W. Washington, D.C. 20460, USA. organizatsii na territorii byivshevo SSSR"
Tel (1202) 2605917; Fax (1202) 2603923. This handbook on ecological organisations in
Eurométaux the former Soviet Union is published by The
European association representing the metal Institute for Mass Political Movements and
industries in Europe. RAU-Press. It gives contact names, the purpose
Further information: of the organizations, and ways of contacting of
Eurométaux, 6th Floor, over 800 groups and institutions.
A venue de Broqueville 12, Further information:
B-1150 Brussels, Belgium. MIPP Company, 2225 Benson Avenue,
Tel (32 2) 775 63 Il; Fax (32 2) 779 05 23. Brooklyn, NY 11214, USA.
European Directory of HazardousWaste Tel (1 718) 3733173.
Management1993/94[1993]C. Newsome(Ed.) The International Occupational Safety
This directory contains descriptions and and Health Information Centre (CIS)
addressesof European and Scandinavian of the InternationalLabourOrganization
companies active in hazardous waste management. Further information:
Further information: CIS, International Labour Organization, ;,
Graj1am & Trotman Ltd., Sterling House, 4 route des Morillons, )
66 Wilton Road, London SWI V 1DE, CH 1211 Geneva 22, Switzerland.
United Kingdom. Tel (4122) 799 67 40; Fax (4122) 7988685.
International Lead Zinc Research Organization,Inc. The Regional Environmental Center for
Further information: Central and Eastern Europe (REC)
2525 Meridian Parkway, PO Box 12036, Promotes cooperation among environmental
ResearchTriangle Park, N.C. 27709, USA. groups and interests in the region, acts as a
Tel (1 919) 361 4647; Fax (1 919) 361 1957. catalyst for developing solutions to
International Lead and Zinc Study Group environmental problems, and promotes
Metro House, 58 St. James's Street, development ofa civil society. REC primarily
London, SWIA 1LD, UK. supports environmental NGOs, cooperates with
Tel (44 71) 4999373; Fax (44 71) 4933725. local authorities, national governments, academic
MetalEurop institutions, and the private sector.
A corporation which produces lead, Further information:
germanium, indium, and zinc. Active in lead, Miklos ter l, 1035 Budapest, Hungary.
zinc, and polypropylene recycling. Tel (361) 250 3401; Fax (361) 2503403.
Further information: Unicorn Publications
Metaleurop S.A., 58 rue Roger Salengro, A nonprofit environmental publishing bouse in )
94126 Fontenay-sous-Bois Cedex, France. Kiev. Unicorn Publications provides readers in
Tel (33 1) 43944700; Fa.t (33 1) 43940381. Ukraine and other countries of the former Soviet
OECD Environment Directorate Block with books and briefings on topics related
EnvironmentalHealthand SafetyDivision to ecological economics, resource conservation,
This division prepared a number of documents mass transportation, renewable energy, organic
on risk reduction activities for specific chemicals agriculture, etc. Unicorn translates classics of
or groups of chemicals. The first Risk Reduction western environmentalliterature into Ukrainian
Monograph was on lead (see background and Russian, adapting them to local conditions
documents). and culture and making them available through
Further information: Unicorn contacts in Germany, the Netherlands,
2, rue André Pascal, UK, USA, Austria and Siovakia.
75775 Paris Cedex 16, France. Further information:
Fax (33 1) 4524 1675. Andriy Glazovoy (044) 4423171;
John Spaulding (044) 2137946.

Environmental and Technologicallssues related to Lead.Acid Battery Recycling : A Workbook for Trainers ..)

Part 4 .l,ljorln(ltion Sources


r]B]; IV:S

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

Risk Reduction Monograph No. 1: Lead Further information:


Background and national experience US EPA,
with reducing risk [1993] Office ofPolicy, Planning and Evaluation,
This document contains infonnati~n on Programme Evaluation Division
.the commerciallife cycle; , Mailcode: PM-223Z
.the environmentallife cycle; 1 Waterside MaIl (WSM), 401 M Street S.W.,
.links between sources and targetsl Washington, D.C. 20460, USA.
.risk reduction and control measurrs and their Tel (1 202) 2605333.
cost/effectiveness; Storage Battery Technical Service Manual [1982]
.conclusions that can be drawn regarding the Published by Battery Council International.
effectiveness ofrisk reduction measures,the This manual gives full information on how to
identification of major exposures that need to handle new batteries, from transportation to
be addressedto help risk reduction, and critical servicing.
infonnation gaps. i Further information:
Further information: 1 Battery Council International, Headquarters,
OECD Environment Directotate, i III East Wacker Drive Chicago, ILL 60601.
Environmental Health and SafetylDivision, Tel (1 312)6446610.
2, rue André Pascal, 75.775Paris ~edex 16, World Directory: Secondary Lead Plants [1994]
France. InternationalLeadandZinc Study Group
Fax (33 1) 45 241675. (ILZSG).
States' Efforts to Promote This publication contains information on ail
Lead.Acid Battery Recycling [1992] smalI, medium and large sized lead smelters and
This report is written to help the S EPA refineries operating solely or partly from
determine how EPA and States can most concentratesand bullion.
effectively promote lead-acid batte recycling. 1t Further information:
describes the car battery recycling hain, ILZSG, Metro House, 58 St. James's Street,
characterizes State lead-acid batte recycling London, SWIA lLD, UK.
requirements, and reviews the erre tiveness of Tel (4471) 4999373; Fax (44 71) 4933725.
State laws in promoting lead-acid attery
recycling. .1i

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaakfor Trainers


Part 4 .Information Sources 11
L:;;I", 1V:7

8 4.4 Handbooks on chemicals,

humans and the environment

Chemical Hazards in the Workplace [1989] Handbook on the Toxicology of Metals


R.M. Scott. 2nd Ed [1986]
Environmental Health Criteria: Lead [1983] L. Friberg; G.F. Nordberg; V.B. Vouk.
and Lead: Environmental Aspects [1989] Health and Environmental Lead in Australia [1987]
World Health Organization, International Programme Australian Academy of Science.
on Chemicai Safety (IPCS). Occupational Medicine: Principles and Practice
Further information: [1988] Carl Zenz (Ed.)
WHO, Distribution and Sales Services, Plomb & Sante dans l'industry: Proteger les
1211 Geneva 27, Switzerland. travailleurs -Pourquoi, comment? [1990]
IARC Monographs on the Evaluation of the ln this book you will find methods to actively
8 Carcinogenic Risk of Chemicals to Humans: Some protect employees from lead exposure, the
metals and metallic compounds Volume 23 [1980] required medical surveys, and ways to recognize
World Health Organization (WHO), symptoms of lead-poisoning. The book is
International Agency for Research on Cancer. available in French.
This publication contains data on lead, Further information:
including the production processes and uses of Centre d'Information du Plomb,
different lead appliances. Péripole 118, 52 rue Roger Salengro,
Further information: 94126 Fontenay-Sous-Bois Cedex.
WHO, Distribution and Sales Services, Tel (33 1) 43944880.
1211 Geneva 27, Switzerland. Proctor and Hughs' Chemical Hazards of the
Workplace [1991]

4.4.1 Journals related to lead

Batteries International. Journal of Power Sources: The International


Quarterly published by Journal on the Science and Technology of
8 Batteries International Ltd. Electrochemical Energy Systems
Further information: Publisher:
Batteries International Ltd., Elsevier Sequoia S.A., P.O. Box 564, 1001
Aberdeen House, Headley Road, Grayshott, Lausanne, Switzerland.
Hindhead, Surrey GU26 6LA, UK.
Tel (44 428) 605536; Fa.\" (44 428) 606339.

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 )

BSB Recycling Zentrum [1989] Further information:


Video on the Blei- und Silverhütte Braubach, Ask for' Free product information No. 251'.
16 min., in German. This video explains the ChemicarEngineering,
processes and technologies used in the BSB hUtte ReaderService Management, PO Box 5273,
to recycle lead-acid batteries and recover their Pittsfield, MA 01203-9916, USA.
constituents with the least environmental impacts. Malette Pedagogique
Further information: This is a train-the-trainer toolkit developed by
Blei- und Silber hütte Braubach, Metaleurop (available in French). It contains
BSB Recycling GmbH, 0-5423 Braubach. educational material for employees in industry on
Reduce worker exposu~eto lead how to protect themselves from lead exposure,
A video and a compliance manual are available including a video, brochures, folders, posters, a
to help operators comply with US Occupational user's guide, and case-studies. It costs FF700.
Safety and Health Administration lead standards. Metaleurop also organizes a two day train-the-
The video explains regulatory requirements, trainer programme on how to protect personnel )
measurement options, techniques for assessing from lead exposure. The seminar costs FF3200.
exposure levels and compliance methods. The Further information:
manual includes detailed background Metaleurop S.A., 58 rue Roger Salengro 94,
information, major requirements, 'fill in the 126 Fontenay-sous-Bois Cedex.
blank' compliance forms, and a glossary of Tel (33 1) 43 944700; Fax (33 1) 43 94 03 81.
terms. Marshall Productions, Trenton, N.J,

..

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers ~

Part 4 .lIifornultiol/ Sources

~
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.

4.5.1 Environmental packages


ENVIRONMENTAL AWARENESS ENVIRONMENTAL AUDITING
PackageEO2 PackageEO4
Understanding is thekeyto effectiveenvironmental Trainees learnhowto makeauditsmoreeffective.ln clearly
improvements -baththroughcertifiedstandards andeffective definedsections, thepackage explainshowto go about
policyimplementation. Thispackagegivesa thorough auditinga site,fromdefiningthescopeandobjectives through
grounding in environmental awareness. Thecasestudies on-siteactivities to reportingandfollow-up work.Thirteen
cover:environmentallaw; globalissues;corporate issues;and casestudiesandexercises, supported byover120slides,
wasteminimization. include:settingupan EMS;auditingforwastedisposai,due
AQUEOUS EFFLUENTS diligence andeffluenœcompliance; reportingauditfindings;
Volume 1: awareness and treatment strategies anddiscussion ofphotographs ofbadpractice.
8 PackageEO1
Engineers learnhowto assessanddealwitheffluent
ENVIRONMENTAL MANAGEMENT SYSTEMS
PackageEO5
problems; seniormanagement gaina soundtechnical and Ifyoualreadyhaveanenvironmental management system,
legalgrounding; andoperators learnwhycomplianœ is thispackage willhelpyougaincommitment fromyourstaff. If
important. Sevencasestudiesdemonstrate howeffective youarejustdeveloping a system,notonlywillyoubenefit
treatment strategies savemoneywhilstbenefiting the fromthetraining,butalsobenchmarking fromthedetailed
environment. Andthetechnicalguidance covers: casestudieswillsaveyoulime.Andif youhavestijl not
characterisation ofeffluents;treatment strategy;
safety;unit decidedwhichsystemto gofor (ifany),thispackage willhelp
operations; andcosts. youmakeaninformed decision.
Volume 2: measurement and monitoring ENVIRONMENTAL IMPACT ASSESSMENT
PackageEO13 PackageEO6
Traineeslearnhowto measureandmonitoreffluents, Thistrainingpackage givesyoua thorough groundingin the
ensuringcompliance andreducingtreatment costs. ElAprocessandtechniques. Produced in conjunctionwiththe
AIR EMISSIONS InstituteofEnvironmental Assessment, thepackageprovides
Volume 1: key issues aneffectivemeansoftrainingail staffconcerned withEIAs.
PackageEO3 Thereareninecasestudiesprovided by leadingenvironmental
Thispackageprovidescomprehensive coverageofgenericair consultancies. Theseintroduce thepracticalaspectsoftheElA
pollutionissuesandtechnologies, backedupwithdetailed processbyexamining projectsinvolving a foodprocessing plant,
sectionson sourœsandtypesofemissions, atmospheric a sewagetreatment works,a coastaldefenœscheme,a pipeline
chemistry, standards andlegislation (UKandEuropean). proposai, anail refineryanda powerstation.
8 Volume 2: monitoring and control WASTE MINIMIZATION
PackageEO12 Package EO7
ThispackagefollowsonfromAEVol.1: keyissues,and Approaches in thepackagevaryfromgoodhousekeeping to
provides detailedinformation on measurement andmonitoring complex techniques suchas lifecycleanalysis.Thistraining
andcontraitechniques, illustratedwithcomprehensive case package showshowto go about il, fromdefininga strategy
studies.Sections on ambientmonitoring, meteorology andair throughto makingsureithappens.
dispersion modelling helpto providea thorough grounding in CONTAMINA TED LAND
thetechnicalissuesassociated withairemissions. PackageEOB
ENERGY MANAGEMENT Trainees learnwhycontaminated landis important, howand
PackageEO11 whya company shouldavoidcontamination, andtheprosand
Energyefficiency affectsthebottomline.Traineeslearnthe consofthekeyremediation techniques. Youwillalsolearn
basictoolsandtechniques for effectiveenergymanagement. howto usethisknowledge to gelthe mostoutofthe
consultants vauuse
For orner form contact: Mark Smith
SafetyHealthandEnvironment
Department.InstitutionofChemicalEngineers
165-189RailwayTerrace.RugbyCV213HQ,UK
Tel +441788578214.Fax+441788560833

8 A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
IV: 10 United Nations Environment Programme' Industryand Environment

4.6 Some background ")

documents on the 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] ,-..

chemical pollutants and wastes. This book is a handbook of industrial ecology


Published by: with numerous checklists for practical use and a
UNEP, Nairobi. concrete example of the Integrated System of
The Earth Summit's Agenda for Change: a plain Environmentalist Business Management (the so-
language version of Agenda 21 and the other Rio called Winter Model), supported by the
Agreements [1993]M. Keating.ISBN2940070008. Commission of the European Communities.
This publication is aimed at facilitating access Published by:
to the very important material contained in McGraw-Hill Book Company (UK) Ltd.
Agenda 21. Life Cycle Assessment: what it is and how to do it
Published by: [1996]UNEPlE
The Centre for Our Common Future, This report is in two parts. The first, Life Cycle
52 rue des Paquis, 1201 Geneva, Switzerland. Assessment: what it is, is concemed with the
concept of LCA, how it is currently practised and

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers

Pltrt 4 .Information Sources

---
1V:11

8 how it is expectedto develop.lt alsoplacesLCA butsystematicmanner.lt illustratesthe problems


in the broaderperspectiveof othertools for involvedandthe kind of resultsthat canbe
environmentalanalysissuchas environmental producedby working througha real LCA thatbas
impactassessment, risk analysisand technology beenusedto assess the environmentalimpactof
assessment. differentlow fat spreads.
The secondpart of the volume,Life Cycle Furtherinformation:
Assessment: how to use it, examinesthe several UNEP lE, Paris,France.
stepsinvolved in makingan LCA in a simplified

8 A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
IV: 12 United Nations Environment Programme' Industry and Environment

')

")

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaakfor Trainers )


Part 4 .Information Sources
.
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"'.AnJ:;iI""?';"""~-';""$~""1" """""'$ffi-""""'~- ~""ffl"""""
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Part 5
Training Malerial
(

5.1 Introduction v:3


5.2 Some ideas for training activities v:4
5.3 Some ideas for preliminary exercises v:6
5.4 Work exercises v:8
( 5.4.1 Obstaclesto a perfect recyclingscheme 8
5.4.2 Case-studyon a (ead-acidbattery recyclingfacility 10
5.4.3Attachmentsto the casestudy 21
5.4.4Life cycle of lead~acidbatteriesand lead 30
5.4.5 Comparison of lead-acidbattery recyclingtechnologies 38

5.5 Some suggestions for answers v:40

(
A Workbook for Trainers : Environmental and Technologicallssues related tô'[êaCi=AêidBatterY Recycling

~--- ---
v:3

8 5 Training Malerial

5.1 Introduction

T his part containsexercisescoveringvariousissuesin lead-acidbatteryrecycling,


divided into preliminaryandwork exercises.Preliminaryexercisesmaybe used
8 to functionas homeworkfor participantsbeforeattendinga workshopor course.

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.

8 A Warkbaakfor Trainers: Environmental and Technologicallssues related to Lead-Acid Battery Recycling

-'","","""""c. ""'""",""",.1,,;lw,"'," ~
v:4 United Nations EnvironmentProgramme. Industry
andEnvironment

"-
52 Some ide as for training ac.livities )

5.2.1 Cleaner Production

C leaner Production is the continuous explainsthe processof the cleanerproduction


applicationof anintegratedpreventative auditstep-by-step.
strategyto processesand products,in orderto Studentscanbe askedto carry out a cleaner
reduceenvironmentalrisks and impacts.The productionaudit at a secondaryleadsmelter,
cleanerproductionapproachmakesuseof usingthe abovementionedmanualas a
many environmentalmanagementtools, guidebook.As a result,the studentscould
including the cleanerproduction audit.Based identify severaloptionsto minimize wastes,
on an overallmassbalanceof a processor site, emissionsand energyuse of the secondarylead
identifying raw materials,products,wastesand smelter.Theseoptionsshould result in more
emissions,andenergyuse,optionsaredevised efficientand costeffectiveoperations. )
to minimize the generationofwastes,emissions This assignmentcouId be a project for a team of
and energy,to improvethe overallperformance students,who tan spendabouttwo months on it.
of the process/site.The Audit and Reduction Sourcesfor informationon cleanerproduction
Manualfor lndustrial Emissionsand Wastes,a optionsare availablefrom EP3, International
joint publicationofUNEP lE andUNIDO LeadandZinc Organization,and otherliterature
sourcesmentionedin Part IV.

5.2.2 A visit to a landfili/lead-acid battery collector

M any lead-acid batteriesarestored


inappropriately.This meansthat they
tan alsobe usedto understandthe importanceof
recyclingmany otherproducts.
eitherend up in ditchesor uncontrolledlandfills, Batteriesthatare dealtwith properly end up at a
or they go to a controlled landfill for household collector,from wherethey aretransportedto a
waste.A visit may be arrangedto investigatethe secondaryleadsmelter.A visit to a lead-acid
destinyoflead-acid batteriesin a landfill. Ask batterycollectorwould give a good idea of the
aboutthe fate of lead-acidbatteries,oncethey practiceof recyclingandwould enhancea basic
have beendumpedin the landfill. This excursion understandingof the environmentaland human
threatsposedby usedlead-acidbatteries.

5.2.3 Breaking a lead-acid battery

onsider examining a usedlead-acidbattery course,the acid shouldbe removedwith tare, and


C in class.You shouldbe ableto getone at a
servicestation.Takethe lead-acidbatteryapart
the wreckedbatteryshouldbe disposedof
appropriatelyafter examination.
during class.While removingthe different
1 . th ~ t f
const.1 uen s rom e a ery, exp am e la e 0
t t fi th b tt Payattention to, and demonstrate,
eachofthem m the secondaryleadsmelter.Of
.safe workingprocedures.

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers ~

Part 5 .Training Material

::;tj"~ c
C
",.; ,,~..
~c"CC,
.v:5

5.2.4 Other recyclable products

W hen considering the broaderissuesof


lead-acidbatteryrecycling,you may want
If recycling schemesfor certainproductsare
not yet in existence,they canbe developed,
to focus your attentionon otherproductsand takingthe lead-acidbatteryrecyclingschemeas
discussin a plenary sessionthe different an example.Ideasfor productsto discussare:
recycling schemesofthese products. wasteoils, batteries(dry cells),plastics,electrical
appliances, and constructionmaterial.

5.2.5 Slags

S lags from secondaryIead-smelters are


generallydumpedin landfills. However,
askthe studentsto gatherinformationon the
nationalregulationsonthe disposaIofsiags, and
8 whenthe heavymetalsin the slagsare otherendusesof slags.Of course,the samecan
sufficiently immobilized,they canbe usedfor be donefor otherproductsfrom lead-acidbattery
otherpurposes,e.g. in road construction.You can recycling:ebonite,PVC,andpolypropylene.

8 i::
A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling

.~,_., ,.""..,... """"


"

v:6 United Nations EnvironmentProgramme. IndustryandEnvironment

5.3 Some ideas for preliminarv exercises )

5.3.1 Introduction

B efore starting a leaming activity, you can


asktraineesto prepareby giving them some
Most ofthese preliminary exercisesrequirethe
traineeto collect informationfrom a numberof
preliminaryexercisesto do. sources.ln orderto give someideasaboutwhere to
You may also wantto askthemto readsome find information,a list of possiblesourcesis given
of the articlesfrom the backgroundreadingin below. You cangive this 'checklist' to the trainees
Part III beforeattendingthe leamingactivity. in advance.Ask themto markthe information
sourcestheyusedfor the preliminaryexercise.

Newspapers Universitylibrary

Internationalorganisations Publiclibrary )/

Ministries Local authorities

CD-ROM Patentoffice

Informationhotlines YellowPages1 phonebook

Magazinesand journals Industries

Interviews Wholesalers

Consumerorganisations (International)databases

Labour unions Industrialorganisations

Chambersof Commerce Non-governmental


organisations )

Other: ServiceSector:

5.3.2 Preliminary Exercise 1

M ake an estimate of the total numberof


batteriesfrom cars which haveto be
the averagelife of lead-acidbatteries.If data is
not available,estimatethe numberof carsby
recycledeveryyear in your country.Go to the consultingstatisticaldatafrom relevantagencies
library, or seekout otherinformation sources,to (which ones?).
find outthe numberof carsin your countryand Explainyour assumptions.

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers --"

Part 5 .Training Material


~;i v:7

8 5.3.3 Preliminary Exercise 2


I nvestigate how the collection ofused lead-
acid batteries is organized in your country.
.Are lead-acid batteries reused in your country,
either by recharging or by cosmetically
Also investigate where lead-acid batteries are cleaning?
collected, how and where they are stored, and .If so, how is this organised?
where they are recycled. Inquire whether it is possible to visit some
.Are ail batteries recycled in your country, or are typical sites which are part of the lead-acid
they (also) exported to other countries? battery recycling network, and discuss the issues
.To which countries are they sent, or from which raised in this preliminary exercise with the
countries do you receive used lead-acid batteries? manager.

5.3.4 Preliminary Exercise 3


T his preliminary exercise should be done in
preparation for the exercise on the lead-acid
grid pasted with metallic lead containing various
elemental additives to increase the anode's
battery recycling facility. ln order to better hardness.The additives used depend on the battery
8 understand the hazards and risks associated with manufacturer. The most commonly used additives
lead-acid battery recycling, you are asked to do a are antimony, arsenic, cadmium (although not in
literature search on the risks associated with the Europe), copper, selenium, and tin.
constituents of lead-acid batteries. Table 5.1 indicates the type and proportions of
The major components of a lead-acid battery constituents of lead-acid batteries. The additives
are: and their typical concentrations ranges are given
.electrodes (lead) in Table 5.2. The figures in Table 5.2 are -
.electrolyte (sulphuric acid) characteristic for Canada and USA. Cadmium is
.casing (plastic). not used as an additive in Europe, because of the
The positive electrode (the cathode) typically environmental problems which occur during
consists of a grid pasted with pure lead dioxide, recycling. Cadmium forms toxic volatiles during
and the negative electrode (the anode) consists ofa lead-acid battery smelting.

1 Searchthe library for information about the hazards related to eachconstituent.


2 Which international organizations can provide information about these hazards?
3 Find articles which discuss cases of lead-poisoning. Could these casesof lead poisoning in any way be
related to the activities of lead-acid battery recycling?

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

Total 100 Co er 0.05

* The category residua/s refers to


ebonite and separators.

8 ;:::.1:
A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling

~",~.. "L,"" """.,"",, ,""","",,,.j """""""",,,,


v:8 United Nations Environment Programme' Industryand Environment

è"
5A Work exercises )

5.4.1 Obstacles ta a perfect recycling scheme

l n many countries, the recycling rate oflead-


acid batteries is around 90 per cent. However,
exercise. You will find this article in the
background reading in Part /II.
despite the fact that recycling networks are weIl The article suggeststhat the lead-acid battery
organized in many countries, recycling rates are recycling network typically consists of four
unlikely to reach 100 per cent. elements: the consumer, the transportation
ln this exercise, you will identify why a network, the battery breakers, and the smelting
hundred per cent recycling rate cannot be operation.
achieved, and why and where in the lead-acid The relationship between these categories is
battery recycling network environmental and shawn in the first figure in the article. Note that
health risks arise. this network is only part of a bigger network for
The exercise can be done individually as weil lead-acid batteries in general. This bigger
as in a group. ldeas for answers are provided by network consists of: '1
the trainer. Other appropriate solutionsmay also .battery manufacturers !

be identified during a plenary session. .consumers (car producers/sellers/buyers)


Read the article on Current Management .lead-acid battery collectors (storage)
Practices for Used Lead-Acid Batteries in and
Canada before answering the questions in this .secondary lead-smelters (see Figure 5.1).

Figure 5.1 The batterylife cycle (Metaleurop,France)


@1J~c
~
P fT ranspo rt ProofTransport
roo

..'
./ 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 '"

Part 5 .Training Material


1: v:9

8 ê1t'j;j;~ 1 (a) Whatconstrai~tsarethereto preventthe consumer{rom deliveringa lead-a

~
'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

8 2 (a) Consideringthe transportationnetwork,whatconstraintspreventdelivery of


the batteriesto the batterybreakeror the secondarylead-smelter?

1 1
(h) What environmentalthreatsand healthrisks occurwhenthe batteriesare stored
commerciallyfor a long time?

1 1
Somesuggestions
for answersto this questionare onpage v:40

3 (a)Consideringthe batterybreaker,whatconstraintsarethereto preventdelivery


of the batteriesto the secondarylead-smelter?

8 1 1

(h) What environmentalthreatsand healthrisks occurwhenthe batterybreaker


keepsthe batteriesfor a long time?

1 1
Somesuggestions
for answersto this questionare onpage v:40

8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Leâd:AcidBâtt~~Recycling


v:lO United Nations Environment Programme' IndustryandEnvironment

5.4.2 Case-study on a lead-acid battery recycling facility )

T his exercise is based on a case-studydescribing the recycling process of lead-acid


batteries at a recycling facility, and is best clone after Preliminary Exercise 3.
The participants will -either individually or in a group -do some exercises, which in
some casesrequire a technical background.

The infonnationneededto answersomeof the with the case-studybeforeaskingthe participants


questionsin this exerciseis provided in the to do the exercises.
attachmentsatthe end of the exercise. The case-studyis basedon the article 'A
The resultsmay be discussedin a plenary modernand low-pollutantsecondarylead smelter
session,and ideasfor answersareagainprovided to beset up in Hungary' included in the
at the endof this Part.The traînershouldwork proceedingsof the World Conferenceon
throughthe exercisestirst to becomecomfortable HazardousWaste:Detection,Control, Treatment
(SeeReferencesin Part [J').

Introduction )

T bis exerciseconcemsa mediumsized


secondarylead-smelterwith an annual
remainingequipment,and emissionsincreased
dramatically.Dustconditionswithin the plant
capacityof 25 000 tonnes,locatednear a becameintolerable,andduring the last week of
recreationarea.The plantprocessesusedlead- 1979,a decisionwasmadeto effectively bypass
acid batteriesand leadscrap.Only the smelting the main pollution contrai facility and continue
and recycling of the usedlead-acidbatteriesare operations.
consideredfor the purposeof this exercise. The bypasscontinueduntil April 1980wh en
Secondaryleadsmeltingis a highly polluting repairswere tinally completed.Severalchildren
process,andhas beenrelatedto manyhealth were hospitalized,andextensiveblood sampling
problemsin the pastand in the present.The revealedthat 95% of ail children in the vicinity
secondarylead smelterdescribedin this exercise had blood leadlevels in excessofO.2mg/1(EEC
was responsiblefor seriousenvironmental limit, 1977).As a consequence, many residents
problemsin the late 1970s.An unfortunate were relocated,andhomesnearestthe smelter
combinationof eventsculminatedin extreme werepurchasedanddestroyed.Severalemission
emissionratesthat poisonedmost of the young contraiprojectswere undertaken.Streetswere
childrenplaying in the vicinity. The tirst ofthese cleanedand dustproducingareaswere watered. 9
eventswasrelatedto a changein ownershipin Homegardeningwasdiscouraged.Clean topsoil,
1977that introduceda new management sandgravel,grassseedingsand watersubsidies
philosophyto the facility. Smeltingcapacitywas wereprovidedto promotethe generalrec'overyof
increasedby about35%,andthe smelter the community.
operatorselectedto install new production Needlessto say,thesecorrectiveactionswere
equipmentbeforeupgradingpollution contrai. very costly. Additionally, the secondarylead
ln the late 1970s,during a period of smelterdevelopeda bad public image.Since
extraordinarilyhigh lead prices,an attemptwas theseaccidents,the plant has beencommittedto
madeto improve air pollution control while the meetingstringentenvironmentalrestrictions,
smelteroperationscontinuedat the maximum especiallywith respectto the following focal
contraI capacity.The resultwasa tire that points:
disabledapproximately60% of the smelter's .complying with the strict regulationson lead
particulateair pollution controlcapability. emission;
However,operationscontinuedwith the .providing for optimally cleanworkplaces.

Environmental and Technological Issues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers --'

Part 5 .Training Mater;a/


ffl~: ,61ig"ïiliBil v:Il

8 Process description

T he processes in the plant involve the


following three operations:
which is then conveyed to the acid tank for
further use. The refmed lead is stored outside to
1 Wrecking the batteries. cool down, after which it is transported to lead
2 Smelting the prepared batteries and lead manufacturers on Tuesdays and Fridays.
slurries by the oxygen process in a short rotary Table 5.3 indicates the type and proportions of
fumace. constituents of lead-acid batteries, based
3 Refining the bullion discharged from the short primarily on the lead-acid automotive battery.
rotary fumace and the scrap lead kettles.
The .layout of the plant described above T bl 53 C t' t t f
h fi Il .. ( F. 53 a e. ans 1uen s a
comprIses t e 0 owmg sections see 19ure . d1 d ' db '
in the attachments). use ea -aGi atterles
.wrecking section with storage areas for battery Corn onent Per Cent Wei ht
scrap and lead slurries; Metalliclead 17
.storage bins for fluxes and recycling products Leadsul hate 50
8 and ~eighing. unit for these materials; Plastic 5

.smel~mg sec~lon; Acid 24


.refinmg section;
..Residuals * 4
.filtenng section.
The batteries collected from scrap yards, Total 100
wholesalers, and service stations are brought to
the facility on Tuesdays. The batteries are stored * The category residua/s refers to ebonite and
in an outdoor stockyard from where they are separators.
transported to the wrecking section's loader by
bulldozer. The stockyard, loader, and crusher are
drained during the wrecking phase to collect acid

Wrecking of the battery scrap

A mOdern and relatively simple process bas


been chosen for battery wrecking,
drainage of the acid. The acid is separated on a
vibrating screen,and discharged into a settling
involving a minimum of machinery. The process tank where entrained slurry is allowed to
bas been exactly tailored to the specified capacity deposit. It is finally stored in a tank for further
8 of 1.0 million batteries/year. use. ln this phase, 95% of aIl acid is separated
The process eliminates operations which -from the batteries.
based on modem findings -are superfluous, such .shredding of the batteries and separation of
as the removal of grid metal and oxide or the polypropylene (and of light plastics
removal of separators. The quantity of acid respectively): the batteries, freed of liquid acid,
removed by the ventilation system is less than 1% reach rotary shears. They are cut up and then
of the total acid content of the batteries, and dropped into a neutralization tank, together with
therefore negligible for the calculation of the the lead paste. The paste is a mixture of lead
mass-balance. However, in order to meet the oxide and lead sulphates. The solids are
most stringent health and safety standards,the discharged from the neutralization tank by
ventilation system is crucial. means of a screw, and then passed on to
The process involves the following operations: intermediate storage. If desired, the floating
.removal of sulphuric acid: the batteries reach a polypropylene may be discharged separately at
spike crusher via a vibrating feeder and a chain this point. The lead paste is collected in the
conveyor. They are perforated to enable

8 A Workbookfor Trainers: Environmental and Technologicallssues related to Lead-Acid Battery Recycling

.._,- ,.",--" ..,. ..,..,


V:12 United Nations EnvironmentProgramme. IndustryandEnvironment

thickenerfrom where it is dischargedto storage and completelybumedwith the heavyplastics, )


for leadfraction. thus utilizing the caloritic value of the latter.
.neutralization oft/le adhering residual Impactson the environmentresulting from
sulphuric acid is carried out in the neutralizing plant operationare avoidedby the following
plant,to avoid volatilizationof SO3insidethe measures:
fumace.The liquid containedin the tank is .the chainconveyorfor batterytransportationis
transferredby pumping,andneutralizedwith sprinkledwith waterto avoid dustgeneration;
hydratedlime. The solids contentis kept .both the spike crusherandthe rotary shearsare
constantby separationof a slurry portion. On operatedat low speed(lessthan 100rpm) (0
average,the ratio of Ca(OH)2to sulphuricacid counteractthe formationof dustand of aerosols;
is 1.2:1 on a weightbasis. .accumulating splashwateris recycled,which
The polypropyleneproductis put into the meansthatno wastewateris generated;
fumace togetherwith the lead-bearingfraction, .plastics with residualleadcontentare Dot
dumped.

Now answerthe following questions:

4 (a) Give three reasons why the sulphuric acid is separated from the lead containing ")
fraction:

(b) What is the main environmentalproblemrelatedto SO3and SO2in the


atmosphere?

(c) ln somesecondarylead smelters,the leadsulphatein the pasteis desulphurized


with Na2CO3.Give the reactionequation,and explainwhy the leadpasteis
desulphurizedbeforethe smeltingprocess:

Somesuggestions
for answersto this questionare on page V:40

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaok for Trainers ~

Part 5 .Training Material


~dl v:13

8 CM 5 Refer 10 Table 5.3. ln this exercise you are asked to calculate a mass balance for

1 the wrecking process for ail components of the lead-acid battery.


'yI
",! ' Assuming an average weight of the lead-acid batteries of 17.2kg, calculate how
many kg ofmetallic lead, lead sulphate/oxide, plastics and residuals per used lead-
acid battery are collected at the end of the wrecking operations.
"Residuals" refers to ebonite and separators (90%), and iron (10%).

8 The answer to this question is on page v:40

l n secondary lead smelters in developing


countries, it bas often been the case that the
in a container at arrivai, and from thereare
transported to a place where the actual breaking
batteries are broken manually, without proper of the batteries takes place. The acid is allowed to
protection for workers. This is to allow release of fUn off to a settling tank through a gutter, where
sulphuric acid before smelting (Greenpeace it is neutralized before being released into a local
report Lead Astray: the poisonous /ead battery waterway. The plastic battery casesare cleaned
waste trade [1994D. by band in rinsing baths at the workplace and
For the next question, assume that -in then stored in a container, which serves as a
developing countries -the batteries are dumped collector for the feed to the smelter.

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):

(b) What protective provisions would be necessaryto prevent exposure to these


hazardous substances?(Seea/so background materia/ and Materia/s Safety Data
Sheets):

Some suggestionsfor answers to this question are on page V:40

8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
v:14 United Nations Environment Programme' Industryand Environment

Smelting the correspondingly prepared batteries and lead


slurries by the oxygen process in a short rotary furnace

T he prepared batteries, a.long with recycling


products from lead retimng (drosses), flue
in this particu!ar ca~eenables the smelting of
battery scrap mcludmg the complete plastic
dusts, and reagents (soda, CaO, SiO2, and Fe- material. This plastic portion is bumed smoke-
chips), are smelted with oxygen in two short free with full utilization of its heat content. To
rotary fumaces. During smelting, the antimony, achieve this, the crushed batteries are charged
arsenic, tin, calcium, aluminium, and other into the fumace with the aid of a vibrating feeder
alloying elements in the grids are oxidized to the (see Figure 5.5 in the attachments) more slowly
slag, while lead is reduced and recovered as a low than usual. During this feeding operation, the
impurity bullion. fumace revolves slowly, either continuously or
The dust and recycling products from the lead intermittently, with the bumer ignited.
retinery make up 10% of the total weight of the During combustion of plastics, the fuel oïl feed
input into the rotary oven, and the reagents added rate is decreased,but the oxygen feed rate is
to the smelter make up a further 5%. increased.
The smelting section consists of a feeding Such retarded feeding and immediate ignition
device and two short rotary fumaces with 3.5m and combustion of the plastic material avoids Dot
diameter, equipped with oxy-fuel bumers of only an uncontrolled, sudden evaporation of the
special design with a capacity of 30-300kg of volatiles contained in the plastic material, but
fuel oil/h and 50-600Nm302/h. also incomplete combustion. These phenomena
The essential features ofsmelting with oxy-fuel can hardly be prevented if the fumace, fully
bumers are: charged with plastic-containing batteries, is
.reducedfuel ail consumption, i.e. from ignited and tumed.
approximately 90kg/t of scrap to approximately The ratio between material and oxygen feed
40kg/t ofscrap; rate and, consequently, the plastics combustion
.shortened chargillg period and, consequently, capacity of the fumace, cao be controlled in such
increase in capacity; a manner that the plastics are bumed unhindered
.reduced generation of dust and therefore, an and smoke-free. As soon as charging of the
increased direct metal recovery (maximum dust fumace and combustion of the plastics have
content in the cleaned waste gas is 2.5mg/Nm3); tinished, the fuel oïl feed rate is increased and the
.and (an important advantage for environmental batch is processed.
protection) reduction in waste Kas volume from ln the short rotary fumace, both oxidizing and
approximately 12m3/kg of fuel oïl when using reducing conditions are produced simultaneously.
air for combustion to approximately 3.2m3/kg The antimony, arsenic, tin, calcium, aluminium,
of fuel oïl when using oxygen. This reduction and other alloying elements in the grids and
ofwaste air, in combination with a lower lead straps is oxidized to the slag while lead is
content of the flue dusts (from 50% to 35%), reduced and recovered as a low impurity bullion.
minimises lead emission. The slag composition is shawn in Table 5.4.
The temperature of the waste air is about 1200°C
when leaving the fumace, and it has:o be rap~dly Table 5.4 Slag composition in per cent weight
cooled down to below 300°C to avold formatIon of
dioxins. Dust from the waste air handling system is PbO 20. 30
caught in a combination of electric precipitators, Sb203 4. 8
bag filters and scrubbers. The dust is then SnO2 0.5 .2
discharged into the short rotary fumace. AS2O3 0.5 .1
Until now, the use of oxygen in a short rotary CaO 4. 10
fumace was limited to the smelting of metal and SiO2 7 .17
lead paste after removal of the plastic
components. The modem oxygen process applied

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers ./

Part 5 .Training Material


r:; v:15

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.

Now answer the following questions.

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?

Theanswerto this questionis onpage v:4/

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:

Theanswerto this questionis onpage v:4/

8 A Workbookfor Trainers: Environmental and Technologicallssues related to Lead.Acld BatteryRecycling

""
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

9 Designthe newprocessflow-diagram of the wreckingprocess.


l, Make a process-flowdiagram,usingboxesto illustratethe separationprocess,
~il and arrowsto indicatethe directionof the flow of the materials.Separation
\fW techniquesbasedon size distributionandhydrodynarniccharacteristicswill suffice
for separatingaIl endproducts.The endproductsare: grids,lead paste,
PVC/ebonite,acid,andpolypropylene.Use water for the different separation
phasesand neutralizationphases:

A suggestedanswerto this questionis on page v:4!

10 Due to the separationphase,polypropyleneandacid canbe processedand sold as


raw materials.
(a) Do you expectthatthe capacityof the smelterswill changedueto the new
separationprocess?

(h) How will the energyconsumptionpertonneof leadchange?

Answersto this questionare onpage v:41

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers

Part 5 .Training Material

...
1 v:17

8 Refining of bullion discharged from the furnace and of scrap lead

R: fining ofbullion is carriedout by a intennediateproductbeinghandledand


tandardprocess(kettle refining) in five transporteduncovered.
kettlesof 50t capacityeach.Refming will include Thehoods(seeFigure 5.6 in the attachments)
the following operations: havebeendesignedin sucha way thatthe
.smelting anddrossing; elements(i.e. an agitator,a pump,or an agitator
.coppeTremoval; joined to a withdrawing unit) canbe integrated
.softening (antimonyremoval); into the hood.The quantityofsucked-offwaste
.final clean-up,alloying andcasting. air is automaticallyadjustedto the minimum
Leadrefining is knownto have environmental volumerequiredfor eachoperation,thug
impactsandto be hazardousto the healthof minirnizingthe overall quantityof wasteair
workers.The removalof reactionand dischargedfrom the refining plant.
intennediateproductsfrom the kettle is The drossesareremovedwith the aid of a screw
particularlydangerousbecauseit ofteninvolves conveyor.Previously,the drosseswereremoved
significantdangerfor the personneldueto the manually,causinga seriousdeteriorationin
occurrenceof lead-bearingdustsandhigh working conditions.The screwconveyorcanbe
8 temperatures. verticallyadjustedfor varyingthe immersion
To eliminatethesedangersand for meetingthe depthinto the fluid layer.The fluid layeris
requirementsof nationallabourregulations,the movedby an agitatortowardsthe inlet openingof
following technicalappliancesareprovided: the screwconveyor,lifted beyondthe kettle rim
.hoods for the kettlesenablingan automatic by the spiralgroovesof the screw,and
adjustmentof the waste-airvolume; continuouslytransferredinto a closedcontainer.
.mechanical removalof drossesand transferof After drossremovalis complete,the container
theseinto closedcontainers; contentis allowedto cool down.The cooled
.pneumatic transportationof the drossesfrom contentis suckedoff with a suitabledeviceand
the containersinto the bins; pneumaticallydeliveredinto a bill.
.transportation of the drossesfrom the bills to Themethodexplainedabovepennits removal
the shortrotary fumace in enclosedconveying of the fluid reactionproductsfrom the melt
units. surfaceand transportationto the biGsection
The abovedescriptionshowsthat aIl process withoutinvolving any dangerfor the operating
operations,including transportation,are staff.
perfonnedin closedcontainerswithout any

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

"""-- "." ",","L~'""""~-


v:18 United Nations EnvironmentProgramme. IndustryandEnvironment

.Sprinkling systemsfor walls areinstalledto accessiblevia gales.and are suppliedwith air )


permit cyclic washing; from outsideover high-dutytilters.
.Floors andplatformsare inclinedtowardsthe Processingofbattery scrapand leadresiduesis
drain andthe channel:waterspraynozzlesare certainlya difficult problemto tope with because
installed at elevatedpoints for cyclic sprinkling oftoxicity of the leadand complicatedhandling
of the surfaces; operations.The plant designdescribedabove
.Essential plantareashave beenlaid out in such showsthatthe applicationof modern
a mannerthatno vehiclesare required,thus technologiesandimprovedworking conditionsto
eliminatingthe entrainmentof dustdeposits; standardtechnologiespermit the erectionof a
.Contrai standsand short-breakrooms,asthey plant atreasonableexpenditurewhich meets
are called.have beenbuilt: theseare only currentjob and environmentalregulations.

Now answerthe following questions.

Il (a) What environmentalthreatsdoesthe secondarylead smelterposeto ils


vicinity? Discuss,for eachstageof the process,the operationsand substances
which may causeenvironmentalpollutionduring normaloperations: )

(h) What aboutwhenthereis a malfunction/accidentin the facility (e.g. tire,


collision, openvalves,etc.)?

1 1
Suggested
answersto this questionare on page v:41

12 (a) For whatpurposescould the slagsbe used,insteadofbeing dumpedat a


.,.
landtill7 )0
,{

(h) What environmentalproblemscanslagscausewhenusedfor thesepurposes,


taking into accountthe origin andcontentsof the slags?

1 1
Suggested
answersto this questionare on page v:42

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbookfor Trainers .)


Part 5. TrainingMaterial
i v:19

8 13 During the smeltingandrefining processandthe recycling of dust,a lot of energy


is used and wasted as heat. Where in the total process could you reuse the heat lost
during smelting, refining and cooling, in order to save energy during the smelting
and refining process?

8
Ideasfor answering this question are on page v:42

14 According to the World Bank report on Occupationa/ Hea/th and Safety


Guide/mes, exposure to employees should never exceed 5Omg/m3.The plant
described above fulfils these norms, thanks to the hood structure above the
fumaces. Before the hood structure was installed, a ventilation system removed the
lead particles from the hall.
Assume that the hall where the two short rotary fumaces are located has a volume
of3600m3. When in operation, the two short rotary fumaces together emit 60g/h of
lead in particle form per 1m3,due to leaks. How many cubic metres must the
ventilation system be able to clear of lead per hour in order to keep the lead
particle concentration below the limit?

A suggestedanswer to this question is on page v:42

8 A Workbook
for Trainers
: Environmentaland Technologicallssues relatedto Lead-Acid Battery

,"c."""'"- -.""_.~..,',,.."..~"~ c."'""."


v:20 United Nations Environment Programme' Industry and Environment

"
" 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.

Give suggestions on how to reduce human exposure to lead through 'good


housekeeping practices':

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 ./

Part 5 .Training Material


ï[.i~ v:21

8 5.4.3 Attachmentsto the case study

Figure 5.2Modelfor air emissioninventoriesand controls


PROCESS UNIT T5P 502 Nax 1 co VOC
(UI kQ/U kg/V kgjU kgjU kg/V kg/V
Fabricfilter tn ofPb 0.07
SECONDARY LEADPROCESSING
Pretreatment
Sweatina furnaœ
Fuqitiveemissions tn ofPb 1.3 Pb 0.55
Uncontrolled tn ofPb 25.5 Pb 6
Control/ed tn ofPb 0.25 Pb 0.06
Smelting
Fuaitiveemissions tn ofPb 8.2 Pb 2.19
Reverberatory Furnace
Uncontrol/ed tnofPb 162 40 Pb 32
8 Control/ed tn of Pb 0.5 40 Pb 0.1
Blast(cupola)
Uncontrol/ed tn ofPb 153 27 Pb 52
Control/ed tn ofPb 1.12 27 Pb 0.15
Refinina
Kettlerefinino
Uncontrol/ed tn ofPb 0.02 Pb 0.006
Control/ed tnof Pb
Kettleoxidation
Fabricfilter tn ofPbO >20.0 PbO >20.0
STORAGE BATTERY PRODUCTION
Uncontrol/ed * 11000batteries 63.2 1 Pb 6.94
Control/ed 1000batteries 3.2 Pb 0.5
PRIMARYZINC5MELTINGPyrometaliuroicaiprocess
Fuaitiveemissions tn ofzinc 3.85
Roasting
Multiplehearthroaster
Uncontrol/ed tnofzinc 113 1100
Cyclone+ ESP tn ofzinc 0.5 1100
8 H1SO4oient tn ofzinc 0.34 33
Suspension roaster
Uncontrol/ed tn ofzinc 1000 1100
Cyclone+ ESP tn ofzinc 4 1100
H1SO4oient tn ofzinc 3 33
Fluidizedbedroaster
Uncontrol/ed tnofzinc 1083 1100
Cyclone+ ESP tn ofzinc 4 1100
HzSO4plant tn ofzinc 3.2 33
Sinterolant
Uncontrol/ed tn ofzinc 62.5 110
Cyclone tn ofzinc 24.1 110
Cyclone+ ESP tn ofzinc 8.25 110

* 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

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbookfor Trainers


Part 5 .Training Materia/
.a~
''''l'''~i~.i.i ~";;**}~~I""&i'
M
":471'7:\'I1!fif~r,
Dlnln e'c'"O:"","\':ccc"'"",""
atenal' v.23
',",iYi"4",h~c,"" .

8 Figure 5.5Shortrotaryfurnacewith hood

8 sourcA
KHD
HUMBDLDT
-WEDAG

Figure 5.6Kettlewith hood,agitatorand removingscrew

source:! .,
KHD 1
HUMBOLDT l'
_WEDAG "

"

8 A Workbook for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling

"",,. ". , "°".""".,


v:24 United Nations Environment Programme' Industry and Environment

')"
Figure5.7MaterialSafetyDataSheetfor lead(inorganic)

Lead (inorganic) ICgC: 0052


CAS# 7439.92.1 Leadmetal
RTECS#OF7525000 Plumbum
ICSC# 0052 Pb
Atomicmass:207.2

Typesof Acute Prevention Firstaid/Firefighting


Hazard/ExposureHazards/Symptoms
FIRE Notcombustible
EXPLOSION

EXPOSURE Preventdispersionof dust!


Stricthygiene!
.Inhalation Headache,
nausea, Localexhaust
or breathing Freshair,rest,andreferfor
abdominal
spasm. protection medicalattention
.Skin

.Eyes
.Ingestion Headache,nausea, Do noteat,drink,or smoke Rinsemouth, inducevomiting
sorethroat, duringwork. (onlyin consc;ouspersans/)
abdominalspasm. andreferfor medicalattention

SpillageDisposai Storage Packagingand Labelling


Sweepspilledsubstance into
containers,carefullycollect
remainder (extrapersonal
protectionP2filterrespiratorfor
harmfulparticles).

Additionallnformation )

l SEEIMPORTANT
INFORMATION
ONBACK 1

ICSC:0052 V1.0 Prepared


in thecontextofcooperation
betweenthe
IMPORTANTLEGALNOTICEONBACK IPCSandtheCommission oftheEuropean
Communities @CEC,IPCS,1990

continued...

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers /

Part 5 .Training Material

"- ..."~.'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 ICSC: 00S2 @CEC, IPCS,1990 Lead (inorganic)

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

Lead (II) Oxide ICgC: 0288


CAS# 1317-36.8 Lead monoxide HAZARDSYMBOL
ICSC# 0288 PbO Consultnationallegislation
EC# 082-001-00-6 Molecular mass: 223.2

Types of Acute Prevention First aid/Fire fighting


Hazard/ExposureHazards/Symptoms
FIRE Notcombustible ln case of tire in the
surroundings,ail extinguishing
agentsallowed.
EXPLOSION

EXPOSURE Preventdispersionof dust.Stricthygiene.Avoid exposureof


pregnantwomen.Avoidexposureof adolescentsand children
.Inhalation Cough,headache, Local exhaustor breathing Fresh air, rest,and refer for
nausea. protection medicalattention
.Skin Redness. Protectivegloves. Removecontaminatedclothes,
rinse skin with plenty of water
or shower.
.Eyes Redness,pain. Safetygoggles. Firstrinse with plentyof water
for several minutes(remove
contactlensesif easily
possible)then take to a doctor.
.Ingestion Abdominalcramps, Do not eat, drink,or smoke Rinsemouth, give nothingto
constipation,
diarrhoea, duringwork. drink,and refer for medical
headache,nausea, attention
vomiting.

Spillage Disposai Storage Packaging and Labelling


Sweepspilledsubstanceinto Separatedfrom sodium, Further information on labelling:
containers,carefullycollect aluminium. Consultnationallegislation.
remainder(extra personal
protectionP2filter respiratorfor
harrnfulparticles).

L. Additionallnformation 1

1 SEEIMPORTANT
INFORMATION
ONBACK 1

ICSC: 0288 V1.0 Preparedin the contextof cooperationbetweenthe


IMPORTANT LEGAL NOTICEON BACK IPCSand the Commissionof the European
Communities@CEC, IPCS,1991

continued
...

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers

Part 5 .Training Materia/


fIli': v:27

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

Notes Aiso consultICSC#0052on lead (inorganic).

Additional
information

ICSC: 0288 @CEC, IPCS,1991 Lead (II) oxide 1

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

Sulphuric Acid ICSC: 0362


CAS# 7664.93.9 Sulphuric acid HAZARD SYMBOL
RTECS#WS5600000 H2SO4 Consultnationallegislation
ICSC# 0288 Molecular mass: 98.1
UN# 1830
EC# 082.001.00.6

Types of Acute Prevention First aïd/Fife fighting


Hazard/Exposure Hazards/Symptoms
FIRE Notcombustible.Many No contactwith flammable No water.
reactions
maycause substances.
tireorexplosion.
EXPLOSION ln casesoftire,keepdrumsetc.
coolby sprayingwithwaterbutno
directcontactwithwater.

EXPOSURE .Avoid ail contact!


.Inhalation Sore throat,cough, Ventilation,local exhaust,or Fresh air, rest, half-upright
labouredbreathing. breathingprotection. position,artificialrespiration if
indicated,and refer for medical
attention.
.Skin Pain,seriousskin Protectivegloves,protective Removecontaminatedclothes,
burns. clothing. rinse skin with plenty of water
or shower,and refer for medical
attention.
.Eyes Pain,severedeep Faceshieldor eye protectionin Firstrinsewith plenty of water
burns. combinationwith breathing for several minutes(remove
protection. contactlensesif easily
possible)then take to a doctor.
.Ingestion Severepain,vomiting, Do not eat, drink,or smoke Rins~mouth, gi.veplentyof.~ater
shock. duringwork. to dnnk,do not Inducevomltlng,
andreferfor medicalattention

Spillage Disposai Storage Packaging and Labelling


Evacuate dangerarea,collectleaking Separatedfrom other materials Unbrea~ab~e packing:putbreakable
liquidin seaiablecontainers(extra (see Notes),store in stainlesssteel pack~gmg Intoclos~dunbre~kable
personal protection:complete containers. container.FurtherInformationon
protective clothingincluding
self- labelling:Consultnational/egislation.
contained breathing apparatus).

1 Additionallnformation 1

1 SEE IMPORTANTINFORMATIONON BACK 1

ICSC: 0362 V1.0 Preparedin the contextof cooperationbetweenthe


IMPORTANTLEGAL NOTICEON BACK IPCSand the Commissionof the European
Communities@CEG,IPCS,1991

continued...

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers

Part 5 .Training Material

~~~.".,,"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.

Thesubstance Ganbeabsorbed intothebody


byinhalation
ofils aerosolandbyingestion.
Physical Boiling point (decomposes) , 340°C
properties Meltingpoint 1O°C
Relativedensity(water = 1) 1.8
Solubilityin water miscible
VapourpressurePa at 146°C 0.13 -,
Relativevapourdensity(air = 1) , 3.4

Environmental Possibleharmfuleffectsto aquaticlife due to acidity.


data
Notes Thesymptoms oflungoedemaoftendo notbecomemanifest untila fewhourshavepassedand
theyareaggravated byphysical
effort.Restandmedicalobservation is therefore
essential.
Neverpourwaterintothissubstanœ: whendissolving
or diluting,alwaysaddit slowlyto the
water.Storein anareahavingcorrosionresistant
concrete
floor.
TransportEmergencyGard: TEC(R)-10b
NFPACode: H3, FO,R2, W
Additional
8 information

ICSC: 0362 @CEC,IPCS,1991 Sulphuric acid

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

5.4.4 Life cycle of lead-acid batteries and lead )

l n this exercise,you areaskedto drawthe life cycle of lead-acidbatteriesand of


lead.The purposeof the exerciseis to understandthe differencesbetweenaproduct
life cycleand a materiallife cycle.

Dependingon the amountoftime available,you The exerciseis bestdone in smallgroups(2-4


may wantto askbroaderquestions,suchas what persons),with half of the groupsdevelopingthe
mining activitiesare involved,how big is the lire cycle of lead-acidbatteries,andthe otherhalf
wastestreaminvolved,how manyproductsare the lire cycle of lead.The trainer will haveto
madeof lead,how muchenergyis usedfor lead- give continuousassistanceasto how detailedthe
acid batteryproduction,how muchpollution does lire cycle shouldbe.
this involve, how muchlead is recycledand how, To facilitatethe exercise,it is advisableto use
etc. This may requireconsiderableliterature eitherblackboardor a flipchart for drawing the
study,so the trainermay wantto collectsome lire cycles.
dataandbackgroundmaterialin advance.Some A recentUNEP publicationon Life Cycle
usefulbackgroundmaterialis attached.UNEP Assessment would makeusefulpreliminary
IE's Industry and EnvironmentNos.2 and3 of reading,andgive furtherideasfor exercisesand
1994focus on recycling. You may find these projects.
issuesusefulfor this exercise.

i~.1 ~~~~.J~~~~ll!~'J~

R eCYCling plays an importantrote in the


conceptof sustainabledevelopment,and
product,focusingon ail constituentsof the
product,or you canlook at the recycling of a raw
especiallythe recyclingofnon-renewable material,focusingon ail its applications.
resources.This becomesclearwhenlooking at Whentalking aboutrecycling lead,you needto
the definition of sustainabledevelopment:a look ataIl the stagesof the lire cycle of lead:
developmentthat meetsthe needs ofthepresent from mining through refming, up to manufacture,
generationswithout compromisingthe ability of consumptionand disposaiof the products in
future generationsto meettheir own needs. which leadis used.
Recycling of materialsandproductsaimsto Whentalking aboutrecycling lead-acid
reducethe environmentalimpactsofthese batteries,you needto look at ail stagesof the lire
materialsandgoods,andto reuseresources. cycle of lead-acidbatteries.Thatmeansyou start
If we don't recyclelead but let it dispersein the atthe excavationand productionof its
environment,this resourcewill eventuallybe constituents:lead,sulphuricacid, PVC,
exhausted. antimony,tin, etc.,and you finish with the
Therearetwo approacheswhenlooking at recycling and/ordisposaIof the different
recycling. You can look atthe recyclingofa componentsof the lead-acidbattery.

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers

Part 5 .Training Materia!

""'""--
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.

Figure 5.10The life cycle

emissions

Production products ..Consumption


Process Process
wastes
product product
primary secondary wastes wastes

8
aste Managemen

\. .( wastes
~ '/

/' , Earth /' ,


miningandcultivation dispersion
andimmobilisation

8 ::'c"jj!!:
A Workbook for Trainers: Environmental and Technologicallssues related to Lead-Acid Battery Recycling

'" ",.~""",'c,.."d", """"'00.,,",.'."""."-


v:32 United Nations Environment Programme. Industry and Environment

"
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

of lead/lead-acid batteries is beneficial for the environment?

.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:

Environment Centre. International Registration ofPotentially Toxic

Environmental Aspects of Selected Non-ferrous Chemicals, United Nations Environment

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

Environment Programme, Industry and ReducingRisk [1993] Paris: Organization for

Environment Centre. Economic Co-operation and Development,

IARC Monographs on the evaluation oft/le Environment Directorate.

carcinogenic risk of chemicals to humons: World Directory: Secondary Lead Plants [1994]

Some Metallic Compounds [1980] Volume 23. Fifth edition. London: International Zinc and

Lead Study Group.

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;::

Analytical tools for identifying Cleaner Production opportunities: Reading Excerpts

Identifying and setting boundaries for life,cycle stages

T he quality of a lire-cycle inventory depends on an accurate description of the system to be

analyzed. The necessary data collection and interpretation is contingent on proper understanding

of where each stage of a life cycle begins and ends.

General scope of each stage

Raw materials acquisition Manufacturing


This stage of the life cycle of a product includes The manufacturing stage produces the product

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

point ofraw materials processing isalso filling/packaging/distribution.

considered part ofthis stage.

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbook for Trainers

Part 5 .Training Materia/


lili v:33

8 Materials manufacture: This step involves Use/reuse/maintenance


converting raw material into a form that can be This is the stage consumers are most familiar
used to fabricate a finished product. For with: the actual use, reuse and maintenance of the
example, several manufacturing activities are product. Energy requirements and environmental
required to produce a polyethylene resin from wastes associated with product storage and
crude oïl. The crude oïl must be refined; consumption are included in this stage.
ethylene must be produced in an olefins plant
and then polymerized to produce polyethylene; Stages of a life cycle
transportation between manufacturing activities .Raw materialsacquisition
and to the point of product fabrication is .Manufacturing
considered part of materials manufacture. -materials manufacture
Product fabrication: This step involves -product fabrication
processing the manufactured material to create -filling/packaging/distribution
a product ready to be filled or packaged; for .Use/reuse/maintenance
example, blow moulding a bottle, forming an .Recycle/waste management
aluminium can, or producing a cloth diaper.
Fillillglpackingldistribution: This step includes Recyc/e/wastemanagement
8 aIl manufacturing processesand transportation Energy requirements and environmental wastes
required to fill, package, and distribute a associatedwith product disposition are included
finished product. Energy and environmental in this stage,as weil as post-consumer waste
wastes caused by transporting the product to managementoptions such as recycling,
retail outlets or to the consumer are accounted composting, and incineration.
for in this step of a product's lire cycle.

Issues that apply to ail stages

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

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbookfor Tra;ners )


Part 5 .Training Material

.,..,
HIa v:35

8 Table 5.7Batteryrecyclingratesin someOECDcountries

1986 1987 1988 1989 1990 1991


Australia 90
Belgium 77
Canada 93
France 80 90
Germanv FR 83 >95
Italy 83
Japan 92.3 92.5 95.2 93.8 92.2
Spain 83
Sweden >100e
United Kingdom 84 93
United States 88.6 91.0 95.3 97.7
e = estimated.

8 Note: Methodsusedto detennineratesmayvary by country.Recyclingratestan exceed100per cent


when storedor stockpiledbatteriesarereturned.
Sources:Country comments,ILZSG, Commissionof the EuropeanCommunities,BatteryCouncil
International,US Departmentof Commerce,US Bureauof Mines,JapanStorageBatteryAssociation,
TonatsuMetallurgicalCompany.
Source:Proceedingsof the REC '93 InternationalRecyclingCongress, "Advancesin Recoveryand
Recycling.Conceptsandtechnology."

8 cC;:
A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
v:36 United Nations Environment Programme' IndustryandEnvironment

Table 5.8Summarytables:lead ')C

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

* Prior to 1991, former Federal Republic only


** Consumption in the Organised Sector
*** Denmark, Norway and Sweden
**** Taiwan (China), Hong Kong, Philippines, Malaysia, Singapore,Thailand and lndonesia
t Data for these countries include total metal consumption in ail forms, i.e. refined lead and
alloys (lead content), plus remelted lead recovered from secondary materials. Data for other
countries include refined lead and alloys only

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Warkbaak for Trainers -'
Part 5 .Training Materia!
r v:37

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

",0"
v:38 United Nations Environment Programme' Industryand Environment

"-
5.4.5 Comparison of lead-acid battery recycling technologies )

T his exercise requires a considerable amount


of work, and is therefore best clone by NOTE
students with a technical background who have The result of this exercise should flot state a
thoroughly studied the background papers. The preference for one technology over the other.
exercise should be tackled as a project, on which The comparison of the different technologies
students are allowed to work in small groups over should reveal thatthey can not easily be
a period of several weeks. It is advisable to compared with each other because of factors like
organise this project in advance,and maybe gel accessibility of the market for recycled products,
the involvement ofsome senior students to assist capacity of the technology, local conditions, etc.
the working groups. The students may need However, you can identify the environmental
considerable guidance from the trainer as to how impacts of the different technologies and develop
detailed the study should be. It"requires close general areas for preferences.
involvement of the trainer.

")
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:

1 The wrecking section of the lead-acid battery recycling facility.


The simplest wrecking operations are designed to release only the sulphuric acid. The most
advanced wrecking operations separate and recover ail the constituents of the battery: acid, PVC,
ebonite, polypropylene, lead scrap, and lead paste. ln between,there is a range ofwrecking operations
using different technologies and resulting in different end products (see background papers).

2 The smelting section of the lead-acid battery recycling facility.


The International Lead and Zinc Study Group distinguishes the following smelter types: blast
fumace, stationary reverberatory fumace, blast fumace and stationary reverberatory fumace, bergsoe
type plant, electric fumace, blast fumace and electric fumace, stationary reverberatory fumace and
electric fumace, Kivcet, and lsasmelt process (World Directory, ILZSG, 1994).

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.

Environmentaland Technologicallssues related to Lead-AcidBattery Recycling : A Warkbaak


for Trainers -"
Part 5 .Training Material
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Y ODare asked to make an evaluation of


existing wrecking operations with respectto
method of comparing the technologies. Use
criteria for capacity, capital investment, energy
their general and environmental performance. consumption, emissions, end-products,
Find literature in specialized libraries or ask for environmental impacts, occupational health, etc.
information about specific wrecking operations at Prepare a presentation of the different wrecking
the patent office. Compare two or three wrecking operations you studied against the criteria you
operations, based on a thorough study. At the developed, and give an indication of the
same time you will have to develop a structured environmental impacts of each of the operations.

r;'~~~~~!I~l!I=~!11 ~~

8 Y ODare asked to make an evaluation of


existing lead smelting technologies with
develop a structured method of comparing the
technologies. Use criteria for capacity, capital
respect to their general and environmental investment, energy consumption, emissions, end-
performance. products, environmental impacts, occupational
Find literature in specialized libraries or ask for health, etc.
information about specific smelting technologies Prepare a presentation of the different smelting
at the patent office. 8ased on a thorough study, technologies you studied against the criteria you
compare two or three smelting technologies, developed, and give an indication of the
which are also considered by the International environmental impacts of each of the
Lead and Zinc Study Group. You will have to technologies.

8 Il'

A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling

.Jo"""'",""""".""","'",,
v:40 United Nations Environment Programme' IndustryandEnvironment

Cc

5.5 50me suggestions for answers )

5.5.1 Obstacles to a perfect recycling scheme

Question 1 (a) Neglect,lackofawarenessof a collectionsystem,the distanceto the collector,and


the lack of an (economic)incentivemay ail contributein preventingconsumersfrom
delivering lead-acidbatteriesto the retailer,collectoror drop-off depot.
(h)Keepingthe batteries'in-house' for a long time may leadto inappropriatedisposai
of the lead-acidbatteries;risks to playing children.Inappropriatestoragemay lead to
accidentalbreakingof the battery.

Question 2 (a)The constraintsincludeneglect,distanceto the batterybreaker,and absenceof


economicincentives(internationallead-pricesor deposits).Theseconstraintsmay
act in combinationwith the possibleabsenceof a batterybreakeror secondarylead-
smelterin the country. ln this case,internationalregulations,geographicaldistance
and cost-benetitoftransportationplay an importantfoie.
(h) Leaking of sulphuricacid ontothe ground,leadingto soil contamination.Exposure
ofworkers to acid and leadwhen inappropriatelystored.Dependingon the location
of the storagefacility, animaisand childrenmaycornein contactwith the batteries,
leadingto exposureto toxins. With rime,thereis an increasedprobability of
degradationof the storedbatteriesbecauseofexposureto the elements,vandalism,
andaccidents(suchastire). The morebatteriesthatare stored,the more seriousthe
consequences of leaks.

Question 3 (a)Decline in internationallead-prices.


Distanceto secondarylead-smelterin
combinationwith the cost-benetitoftransportinga small numberoflead-acid
batteries(seeanswerto Question2a).Note the problemwhich ariseswhen lead loses
its value.
(h) Seeanswerto Question2b.

5.5.2 Case-study on a lead-acid battery recycling facility

Question 4 (a) Whensulphuricacid is allowedto enterthe rotary furnace,it causesSO3


emissions.If the sulphuricacid is removed,lessenergyis neededto smeltthe lead
fractions.Sulphuricacid canalsobe recycledcosteffectively.
(h)The main environmentalproblemis the formationof acid Tain.
(c) PbSO4+ Na2CO3~ PbCO3+ Na2S04
See3.4.4Low wastetechnologyfor reprocessingballery scrapin Part 3: Technical
BackgroundPapers for an explanationofwhy the leadpasteis desulphurizedbefore
the smeltingprocess.

Question 5 1 Weightof usedlead-acidbattery * fraction of constituent= kg constituent.

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

Part 5 .Training Material


rè:iEl; v:41

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

Part 5 .Training Material

" " "-"_.~." """--".""""'.."_.


.;i v:43

8 Question 15 Frequentcleaningof areascontaminatedwith lead,usingmethodswhich do not


spreadthe lead,suchasmobile or fixed vacuumcleaningapparatuswith high
efficiencyfilters or wet cleaningmethods.
Isolateeatingandchangingareasfrom areasof leadwork andprovide suitable
facilities to store food, drink andsmokingmaterials.
Do not allow smoking,drinking or eatingin work areas.
Washingofhands and removalof contaminated clothingbeforeenteringeatingarea.
Providework clothing whichcanbe keptseparatefrom normalclothes.
Removalof contaminatedclothingandshoweringprior to leavingthe workplace
premises.
Washingof contaminatedclothing at the workplace,so asto minimisethe likelihood
of spreadingthe contaminationto thehome.
Make surethat personalprotectiveequipmentis properlymaintainedand stored.
Setproceduresfor regularplantmaintenance.
Follow operationinstructionscloselyin orderto avoid lead dustdispersionduring
variousbatchand transferoperations.

8 Question 16 Don't use PVC,becauseit is not beingrecycled.Try to useothermaterialsso slags


do not containheavymetals.Designbatteriesso that theycanbe repairedratherthan
recycled.
The useofPVC separators resultsin considerableeconomicand technicalproblems
(difficulties in dustcollection,equipmentcorrosion,necessityof specialstorages,etc.)
during scraptreatment.Replacingtheseseparatorswith oneswhich do not contain
chlorinecutsthe costsfor lead productionfrom secondaryraw material.
At the sametime,the useofnew parts in lead-acidbatteriescomplicatesthe scrap
treatment.For example,the useof coppercontactpins insteadof lead canmake scrap
separationdifficult, andincreasesthe yield of drossesandmatte.The mostserious
difficulties canbe causedby additionto leadalloys of suchelementsas cadmium,
tellurium, or arsenic.Theseelementsand their compoundsaremore volatile andtoxic
thanleadand its compounds.

Question 17 97.2%of alllead is recycled.Assumethat 97.2%of metallic leadand 97.2%of lead


from leadpasteis beingrecuperated. Calculatethe fractionof lead in leadpaste,then
calculatethe total initial amountof molecularlead.97.2%of this total canbe usedfor
8 productionof newbatteries.

8
0 .
1
Appendices
~

~
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Jff
UNEF

Appendices

"

1 Supporting Documentsfor this Package 3


II List of Training ResourcePackagesavailable from UNEP lE 5
III About UNEF Industry and Environment 7

l A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling
",,-," """ 3

Appendices

8
Appendix 1
Supporting Documents for tbis Package

The following documentsareavailableto supportfurtherwork usingthis package:

8 Promoting WasteRecycling:Part 1 [1994]


ln lndustry and EnvironmentVol. 17,No. 2.
Promoting WasteRecycling:Part11 [1994]
ln lndustry and EnvironmentVol. 17,No. 3.
Gestionde l'environnementdansles usinesde recyclagedesbatteriesplomb-accide
[anticipatedpublicationdate1996]UNEPlE.
Life CycleAssessment:what it is and how to do it [1996]UNEP.

8 A Warkbaak for Tra;ners: Environmental and Technologicallssues related to Lead-Acid Battery Recycling

--~-,...'".
4 United Nations Environment Programme' Industry and Environment

"

Environmental and Technologicallssues related to Lead-Acid Battery Recycling : A Workbookfor Trainers )

Appendices

..." '"Co
5
Appendices

8
Appendix II
List 01Training Resource Packages
available Irom UNEPlE

T he following training resourcepackageshavebeendevelopedby UNEP lE. They aIl use


interactivetraining methodologiesto explainthe subject,andareaimedat educatorswho,
althoughtechnicallyskilled, may not havespecializedknowledgein ibis particulararea.
The packagesareavailablefrom UNEP lE.
Sometrainers' packagesare still underdevelopment,
andusersareencouraged
to assistUNEP to
8 bring theseto a fmal stageof publication.

Due to the costofprinting of the packages(between100and 400pages),the completeddocuments


areoffered for saleto mostusers.However,a limited numberof draftpackagesarefree of chargeto
userspreparedto contributeto their furtherdevelopmentthroughreview,field testingandadding
material.Assistancewith translationwould alsobe welcome.

CleanerProduction: a Training Resource exercises.110pages.Price$120. This package


Package[1996] First Edition. Contains alsohelpsto explainthe APELL programme.
backgroundreading,transparencies, Risk ManagementofContaminatedIndustrial
bibliography,and work exercises.110pages. Land: a TrainingResourcePackage[1996]
Price $120 (English,Spanish).This package First Edition.Containsbackgroundreading,
canbe usedwith the workbooksbelow. casestudiesandwork exercises.110pages.
Trainer 's Workbookon Cleaner Productionin Price$120. English,Spanish.
Leather Tanning [1996] First Edition. Contains HazardousWaste,PoliciesandStrategies:a
backgroundreading,casestudies,work TrainingManual [December1991]TRIO.
8 exercisesandanswers.120pages.Price$120. Containsbackgroundreading,casestudies,
Trainer's Workbookon CleanerProductionin work exercises,referencetablesand
the Brewing Industry [1996] First Edition. bibliography.250 pages.Price$120. English,
Containsbackgroundreading,casestudies, French,Spanish.
work exercisesandanswers.75 pages. Landjill ofHazardousIndustrial Wastes:a
Price$100. TrainingResourcePackage[March 1994]
Trainer's Workbookon CleanerProductionin TR17.Containsbackgroundreading,case
Textile WeIProcessing[August 1995]First studies,work exercises,referencetablesand
Edition. Containsbackgroundreading,case bibliography.315pages.Price$120.
studies,work exercises,answers,references. Environmentaland TechnologicalIssues
140pages.Price$120. relatedto Lead-Acid BatteryRecyc/ing:
Management ofIndustrial AccidentPreventioll TrainersWorbook[1996] First Edition.
and Preparedness:a TrainingResource Containsbackgroundreading,transparencies,
Package[1996] First Edition. Contains bibliographyandwork exercises.130pages.
backgroundreading,casestudiesandwork Price$120.

8 A Workbook for Trainers: Environmental and Technologicallssues related to Lead-Acid Battery Recycling

"'"' _."", '


6 United Nations EnvironmentProgramme' IndustryandEnvironment

-.,

Environmental Management ofMining Sites: a Training Manual on Chillers and Refrigerant c)


Training Manual [1995]UNEP/DDSMS. Management[1994]PriceFF425/us$85for
Containsbackgroundreading,transparencies, developedcountries.
casestudies,work exercisesandanswers. Training Manual on GoodPracticesin
200 pages.Price$160. Refrigeration [1994]Price FF400/US$80 for
Environmental ManagementSystems:Training developedcountries.
ResourceKit [1995]UNEP/ICC/FIDIC. EnvironmentalImpactAssessment:a training
Containsbackgroundreading,transparencies, resourcemanual[1996] Preliminaryversion.
casestudies,work exercises,bibliography. Available from UNEP Environmentand
492 pages.Price$190. EconomicsDepartrnent,UNEP,Nairobi.
Aerosol ConversionTechnologyHandbook [1994]
PriceFF225/us$45for developedcountries.

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

I ndustry and Environment was establishedby UNEP in 1975to bring


industry and government together to promote environmentally sound
industrial development.

8 UNEP lE is locatedin Parisandils goalsareto: the transferof infonnationandthe sharingof


1 encouragethe incorporationof environmental knowledgeand experience,UNEP lE bas
criteria in industrialand developmentplans; developedthreecomplementary tools:
2 facilitate the implementationof proceduresand .technical reviewsandguidelines;
principles for the protectionof the environment; .Industry andEnvironment:a quarterlyreview;
3 promotethe use of safeandcleantechnologies; .a technicalquery-response service.
4 stimulatethe exchangeof infonnationand ln keepingwith ils emphasison technical
experiencethroughoutthe world. cooperation,UNEP lE facilitatestechnology
UNEP lE providesaccessto practical transferandthe implementationof practicesto
infonnationanddevelopsco-operativeon-site safeguardthe environmentthroughpromoting
actionand infonnationexchangebackedby awareness and interaction,training anddiagnostic
regularfollow-up andassessment. To promote studies.

Some relevant UNEP lE publications


Referto Appendix Ilfor trainers' packages.For comp/ete/ist, refer to publicationscatalogue.
Industry and Environment [quarterly]dealswith Energy, Efflciencyand ClimateChange[1991]
8 issuesrelevantto industrialdevelopment,such UNEP/IPIECA.95pp.
asauditing,wastemanagement, industry- Hazard Identification and Evaluation in a Local
specific problems,and environmentalnews. Community: Technica/ReportNo. /2 [1992]
GovernmentStrategiesand Policiesfor Cleaner 86pp.
Production [1994] 32pp. Hea/thAspectsofChemical Accidents:
Cleaner Production WorldwideVol. 1and Il guidanceon chemical accidentawareness,
[1995]48pp. preparednessand responsefor health
Life CycleAssessment:what it is and how to do professionalsand emergencyresponders
it [1996]92pp. Technica/ReportNo.19 [1994] A joint
Audit and Reduction oflndustrial Emissions IPCS/OECD/UNEP/WHO publication:OECD
and Wastes:Technica/ReportNo. 7 [1991] EnvironmentMonographNo. 81. 47pp.
UNEP/UNIDO. 127pp. EnvironmentalAspectsof lndustrial Wood
Monitoring oflndustrial Emissionsand Wastes: Preservation:a technicalguide Technica/
Technica/ReportNo.27 [1996] ReportNo. 20 [1994] IO5pp.
UNEP/UNIDO. 188pp. The TextileIndustry and the Environment
Technica/ReportNo.16[1994] 120pp.

8 A Warkbaak for Trainers : Environmental and Technologicallssues related to Lead-Acid Battery Recycling

.."c~c"~" ...,.~". w.~" ~..~~ ,"j,-


8 United Nations Environment Programme elndustry and Environment

Environmental Managementin the Brewing CompanyEnvironmental Reporting Technical !î


Industry TechnicalReportNo.33 [1995] 120pps. ReportNo. 24[1994] 118pp.
Storage ofHazardousMaterials Technical From Regulationsto Industry Compliance:
ReportNo. 3 [1990] Building Institutional Capabilities Technical
Campa/liesOrganization and Public ReportNo. Il [1992] 62pp.
Communicationon Environmental Issues
TechnicalReportNo.6 [1991] 130pp.

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
...

8 A Workbookfor Trainers: Environmental and Technologicallssues related to Lead-Acld Battery Recycllng

-..~~""" ..,"",,""O"'_"W,"_hn, ""'"

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