Power of Battery Recycling: Sustainable Solutions for a Cleaner Future

Battery Recycling: an Environmental & Economically viable option for all Stakeholders

Battery Recycling by Type

Most types of batteries can be recycled. However, some batteries are recycled more willingly than others, such as button cells and lead-acid automotive batteries and button cells. Rechargeable batteries such as nickel-cadmium (Ni-Cd), nickel metal hydride (Ni-MH), lithium-ion (Li-ion), and nickel-zinc (Ni-Zn) are also eligible for recycling. There is currently no cost-neutral recycling option available for replaceable alkaline batteries, though consumer disposal recommendations vary by region. 

Lead-Acid Battery

Lead serves as the primary raw material in lead-acid storage batteries, rendering them highly recyclable and advantageous. Recycling these batteries not only holds social and environmental significance but also proves economical across the value chain. Manufacturers have initiated buyback programs to encourage battery recycling, aiming for sustainable practices.

Recycling Process and Benefits – Lead-acid storage batteries boast a remarkable recycling rate of up to 97%, with about 70% of their weight constituting reusable lead. This straightforward recycling process contributes to over 40% of the lead supply coming from recycled batteries. Manufacturers and retailers are streamlining collection efforts, ensuring convenience for consumers and facilitating buyback schemes.

Environmental Impact and Economic Viability – The core objective of recycling is to prevent hazardous materials from contaminating water bodies and the environment while harnessing materials like lead for new battery production. Lead-acid battery recycling proves not only essential but also cost-effective, as lead extraction is relatively simple and allows for multiple reuses. Profitable ventures, such as smelting units in India, thrive on the recycling of lead from batteries, underscoring its economic feasibility.

Despite the generally high energy costs associated with battery recycling, lead-acid batteries stand out as a notable exception due to the ease of lead extraction and reusability. This underscores the critical role of lead-acid battery recycling in fostering sustainability and economic growth, setting a precedent for responsible resource management in the battery industry.

Silver oxide Battery

This battery is used most frequently in watches, toys, and some silver oxide batteries, medical devices containing a small amount of mercury. Most authorities regulate their disposal and handling to reduce the discharge of mercury into the environment. Silver oxide batteries can be recycled to recover the mercury.

Steps of Recycling of Lead-acid Storage Batteries

Pre-Sorting

Pre-Sorting is done for safety reasons and to separate hazardous material. Lead acid is benign but toxic. Recycling starts by sorting batteries into chemistries. Collection centers place lead-acid, into designated drums, sacks, or boxes.

Battery identification and labeling

X-ray technologies are used to separate batteries.

Lead-acid is the best battery that can be recycled with profitability. With almost 100% of lead-acid being recycled.

Thermal Oxidation

The following steps commence with the elimination of combustible materials like plastics and insulation utilizing a gas-fired thermal oxidizer.

This exposes the real and open cells with metal content.

The fixed cost for recycling one ton of batteries typically falls within the range of ₹70,000 to ₹1,40,000. Ongoing efforts aim to reduce this cost to approximately ₹21,000 per ton, encompassing transportation expenses.

To simplify transportation, manufacturers have set up smelters plants in strategic geographic locations. Modern and hi-tech lead smelters are present near Bangalore and Pune, where recycling of old batteries is done and the lead is sold back to us in an ingot form.