This work aims at recovering lead metal from used lead acid batteries, by the hydrometallurgical method. The treatment of used batteries for recovering lead is important from the point of view of lead production as well as pollution abatement as otherwise the battery scarp leads to serious disposal problems. As the Pyrometallurgical and other methods suggested in the past decades, are found to be impracticable, the above new method was used. The recovery of lead metals from lead acid batteries by electrochemical method comprising two successive steps of lead leaching and electrode position. It is found that 95% of lead metal was leached by 2M of nitric acid and the electrode position step more than 90% of lead metal can be recovered with low current efficiency from the leaching solution. The method adopted seems promising and has great potential for removal of lead from used lead acid batteries.

 

 

TABLE OF CONTENTS

TITLE PAGE

APPROVAL PAGE
DEDICATION
ACKNOWELDGEMENT
ABSTRCT
TABLE OF CONTENT

CHAPTER ONE

• INTRODUCTION
• OBJECTIVE OF THE STUDY
• SIGNIFICANCE OF THESTUDY
• PROBLEMS AND LIMITATION OF THE STUDY
• ADVANYTAGES OF THE STUDY
• SCOPE OF THE STUDY

CHAPTER TWO               

LITERATURE REVIEW
2.0      LITERATURE REVIEW
2.1      OVERVIEW OF DISCARDED CAR BATTERIES
2.2     RECOVERING AND PROCESSING MATERIALS
2.3     BATTERY RECYCLING
2.4     BATTERY RECYCLING BY TYPE
2.5     OVERVIEW OF LEAD–ACID BATTERY
2.6     HISTORICAL BACKGROUND OF LEAD ACID BATTERY
CHAPTER THREE

3.0        METHODOLOGY
3.1           EXPERIMENTAL INVESTIGATION

CHAPTER FOUR
RESULT ANALYSIS
4.1   RESULTS AND DISCUSSION

CHAPTER FIVE

• 5.0      CONCLUSIONS AND REFERENCES
• CONCLUSIONS

5.2     REFERENCES

CHAPTER ONE

• INTRODUCTION

The electrical and electronic waste (e-waste), like a municipal solid waste (MSW), is one of the fastest growing advanced types of solid waste streams in the urban environment, worldwide. Globally, e-waste is growing by about 40 million tons (MT) a year. In India e-waste generation is growing at about 15% and is expected to cross 800,000 tons per year in 2012. The composition of e-waste is very diverse and contains over 1000 different substances, which falls under organic and inorganic fractions [1]. Heavy metals form a significant part of inorganic fraction amounting to 20-50%, which may consists of hazardous metallic elements like lead, cadmium, chromium, mercury, arsenic, selenium and precious metal like silver, gold, copper and palladium. Pondicherry, which is one among the four regions constituting the Union Territory (UT) of Pondicherry. The population of Pondicherry municipality is 221,000. The MSW generated is about 175 tons per day and the per capita generation of e-waste is 0.578 kg per annum [4].
A previous study conducted by Pondicherry Engineering College (PEC) has revealed that MSW management. Self is far from satisfactory, leave alone E-waste management. However, in recent times the need for managing MSW and E-waste has been realized by the authorities, but no concrete action plan has been initiated. As part of continuous research on MSW and E-waste management, the Department of Civil Engineering, PEC, has initiated a series of scientific studies. Based on preliminary survey, the importance of recovery of lead from used/discarded lead acid batteries has been taken up for investigation. Lead acid batteries have lead alloy metal, lead sulfate, micro porous paper and plastic. Every year, the industry produces about 2.5 MT of lead throughout the world. Most of this lead is used for batteries. The remainder is used for cable coverings, plumbing, ammunition, and fuel additives. Other uses are: as paint pigments and in PVC plastics, x-ray shielding, crystal glass production, and pesticides. Heavy metal ions can be removed or recovered by several techniques such as: chemical precipitation, ion exchange process, adsorption by biosorbents and electrochemical methods. In electrode position, lead ion in solution can be deposited on the cathode. If the electrolyte is acid, the reduction of hydrogen ions to hydrogen gas also takes place in the reaction [2], [3]. Metals can be recovered by the metallurgical method, which can be carried out  in  three  ways,  namely,  (i)  Pyrometallurgical or  fusion  reduction  method,  (ii)  Hydrometallurgical or electrolytic method and (iii) Biometallurgical method. Of the above, hydrometallurgical method is widely adopted for extracting a large number of metallic elements. In view of the above, in this study, the above method is adopted to extract lead from lead acid battery and the performance of the method has been assessed and reported.

1.2                                          AIM/OBJECTIVE OF THE STUDY
The aim of this research is to recover lead from discarded sulfated lead-acid batteries in order to save the energy and money. In this work, the effect of inverse charge on the reactivation of sulfated active materials has been investigated. At first, the battery is deeply discharged and the electrolyte of battery is replaced with a new sulfuric acid solution of 1.28 g/cm3.

1.3                                           SIGNIFICANCE OF THE STUDY
Recycling is an important part of keeping our environment safe. By definition, recycling is the process of converting waste into reusable material. It decreases both the need for new materials and the environmental harm that comes from improperly disposed of materials.
The lead is melted. The lead included in your battery’s grid, terminals, and posts gets melted into lead ingots. These are used to form new battery grids, and retained lead oxide can be used in future batteries as well.
The battery acid is neutralized and processed. The final recycled element, your battery’s electrolytes, is most important. Lead-acid batteries use sulfuric acid as their electrolyte conductor. Sulfuric acid is strong enough to burn through iron and can create toxic fumes if handled improperly.
This old battery acid can be neutralized in two ways. First, it can be neutralized with a basic (to counteract the acidic electrolyte) compound which transforms it into water. The water is then treated, clarified, and tested before being released into sewer systems. The second way involves a more modern recycling process. The sulfuric acid is processed and converted into sodium sulfate, a substance which is used in laundry detergent, glass, and textile manufacturing.

1.4                             PROBLEMS AND LIMITATION OF THE STUDY
Recent events where Li-ion batteries have been included the lead-acid battery input stream at secondary lead smelters have resulted in fires and explosions (17) and have identified issues with the system on which future Li-ion recycling can be modeled. This contamination of the input stream may be the result of honest mistakes due to the fact that many current Li-ion batteries are indistinguishable from lead-acid batteries. It may also be a consequence of recyclers paying for their desired input material (Pb-acid batteries) and charging for disposition of other less-desired input material, resulting in contamination to avoid these fees. Regardless of the reason, such events pose a serious danger and must be prevented. In practice, however, it is difficult to detect due to the similar structure of the batteries and that batteries are often delivered to recyclers in huge loads (over 3,000/hour– up to 70,000/day). This problem could be reduced if there were a profitable outlet for the recycling of Li-ion batteries or if all Li-ion batteries could be recycled to high-value products.
Lead is easily melted down for reuse and therefore lead batteries are rarely discarded as waste. Recycling lead by melting down used batteries (also known as secondary smelting) is a profitable business throughout the world. Unfortunately, recycling lead from used batteries is known to result in high lead exposures that can cause severe health effects and contaminate the environment unless adequate equipment is used and procedures to minimize emissions are followed.

1.5                                            ADVANTAGES OF THE STUDY
For automotive batteries, however, the environmental benefits are clear, although they vary with battery type and recycling method. There are also potential economic benefits. If usable materials can be recovered, less raw material needs to be extracted from the limited supplies in the ground. Further, domestic recycling reduces the the raw materials imported from abroad, improving our balance of payments. In addition, significant environmental benefits can be obtained by recycling elements obtained from mining and processing ores (e.g., SOx emissions from smelting of sulfide ores to yield copper, nickel, and cobalt) (4) since the environmental effects of recycling are generally smaller than those from primary production. There are, of course, exceptions, such as recovering lithium from pyrometallurgical process slag. Recycling of materials also avoids processing costs for waste treatment. In addition, some spent batteries (5) are classified as hazardous waste, which increases transportation, treatment, and disposal costs, and requires additional effort to achieve regulatory compliance.
Lithium-ion batteries are starting to be used in significant quantities for automotive propulsion. Because these batteries are expected to last the life of the vehicle and may subsequently be used for utility energy storage, they will not be ending their useful lives in large numbers for on the order of 10 years. What steps can be taken to ensure that these spent Li-ion batteries are recycled at the end of their useful life. In an ideal system, these batteries would be sent for responsible recycling and not exported to Third World countries with less stringent environmental, health, and safety regulations. Methods are needed for safe and economical transport and processing of the spent batteries, as well as environmentally sound recycling practices. In addition, the recycled product needs to be of sufficient quality to find a market. Fortunately, recycling system for lead-acid and Nickel-Metal Hydride batteries are already in place and can provide lessons that can be applied to recycling Lithium-ion batteries.
1.6                                                   SCOPE OF THE STUDY
A process for recovering lead from scrap lead-acid batteries comprises smelting whole unbroken batteries in a blast furnace having a configuration which minimizes the amounts of flue dust produced. The volatile organic material produced by the combustion of the battery cases and separators and entrained in the furnace exhaust gases are ducted to an after-burner and burned to carbon dioxide while any sulfur dioxide gas combines with metal oxides to form solid metal sulphate including lead sulphate particles which can be collected and recycled into the furnace for further lead recovery. The blast furnace utilized in the lead recovery process is characterized by its wide shaft causing gases to rise at a low velocity, thus enabling a longer time for hot reducing gases generated in the smelting zone to contact and give up heat to the descending charge of scrap batteries, resulting in the maintenance of a cold furnace top. Most of the volatilized lead recondenses on the cold charge, reducing significantly the amount of lead-containing flue dust.

REFERENCES

• Cowie, Ivan (13 January 2014). "All About Batteries, Part 3: Lead-Acid Batteries". UBM Canon. Retrieved 3 November 2015.
• Crompton, Thomas Roy (2000), Battery Reference Book, Newnes
• Linden, David; Reddy, Thomas B., eds. (2002). Handbook Of Batteries (3rd ed.). New York: McGraw-Hill. p. 23.5. ISBN 0-07-135978-8.
• http://lead-acid.com/lead-acid-battery-history.shtml "The History of the Lead Acid Battery" retrieved 2014 Feb 22
• "Gaston Planté (1834-1889)", Corrosion-doctors.org; Last accessed on Jan 3, 2007
• For one example account of the importance of battery SG to submariners, see Ruhe, William J. (1996). War in the Boats: My World War II Submarine Battles. Brassey's. p. 112. ISBN 1-57488-028-4.

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