Batteries, plastics used

The electrowinning process developed by Ginatta (34) has been purchased by M.A. Industries (Atlanta, Georgia), and the process is available for licensing (qv). MA Industries have also developed a process to upgrade the polypropylene chips from the battery breaking operation to pellets for use by the plastics industry. Additionally, East Penn (Lyons Station, Pennsylvania), has developed a solvent-extraction process to purify the spent acid from lead—acid batteries and use the purified acid in battery production (35). 

Battery assembly using cylindrical cells varies, and ceU-to-ceU connections are spot welded after using either flat tabs or cup tabs. CeU-to-ceU insulation is effected either by using plastic cell jackets (shrink-on) or by inserting cells in plastic modules with each cell occupj-ing its own cavity. 

PLI battery (plastic lithium ion battery) A lithium ion cell which uses a polymer electrolyte. 

BASF low-temperature pyrolysis of mixed plastics, using a battery of stirred tank reactors for liquefaction. 

Advantages to plastic cell cases are cost and electrical isolation in the 320 V and higher battery packs common to today s electric vehicles, where even high resistance leakage currents to other vehicle components must be considered. Further design considerations for plastic cell cases include development costs for permanent molds, gas permeation, thermal conductivity, and sufficient plastic thickness for gas pressure containment without can wall bulging. NiMH battery modules using plastic cell cases are shown in Fig. 30.3. 

Zinc is also used extensively to galvanize other metals such as iron to prevent corrosion. Zinc oxide is a unique and very useful material for modern civilization. It is widely used in the manufacture of paints, rubber products, cosmetics, pharmaceuticals, floor coverings, plastics, printing inks, soap, storage batteries, textiles, electrical equipment, and other products. Lithopone, a mixture of zinc sulfide and barium sulfate, is an important pigment. 

Polypropylene. Polypropylene (PP) is used ia packagiag appHcations as films and ia rigid containers. Battery cases could be considered another packagiag appHcation. Dead batteries are often collected at the poiat of sale of new batteries. In the U.S., some states have laws mandating this. Lead, acid, and plastics, particularly PP from battery casiags is recovered and recycled (3). Care must be taken to limit worker exposure to lead duting this process (44). PP is also recovered from bale wrap and other PP fabrics used for wrappiag ia the textile iadustry and from other containers (45). 

Total consumption of lead in the United States in 1993 reached 1,318,800 t. Of this, 766,000 t (58%) is allocated to battery use suppHed as either a mixed oxide or as metal. Approximately 95% of batteries are recycled and the lead recovered. In 1993, 908,000 t of lead came from secondary smelters and refiners compared to 350,000 t originating in primary mines and smelters (39). Approximately 51,000 t of lead was consumed in U.S. production of all oxides and chemicals appHcable to all industries other than batteries. Estimates include 8000 t for plastics, 6000 t for gasoline additives, 2000 t for mbber, and 30,000 t for ceramics, glass, and electronics. Lead is not used to any extent in dispersive appHcations such as coatings. 

Lead forms a normal and an acid sulfate and several basic sulfates. Basic and normal lead sulfates ate fundamental components in the operation of lead-sulfuric acid storage batteries. Basic lead sulfates also ate used as pigments and heat stabilizers (qv) in vinyl and certain other plastics. 

The tubular positive plate uses rigid, porous fiber glass tubes covered with a perforated plastic foil as the active material retainer (Fig. 2). Dry lead oxide, PbO, and red lead, Pb O, are typically shaken into the tubes which are threaded over the grid spines. The open end is then sealed by a polyethylene bar. Patents describe a procedure for making a type of tube for the tubular positive plate (90) and a method for filling tubular plates of lead—acid batteries (91). Tubular positive plates are pickled by soaking in a sulfate solution and are then cured. Some proceed directiy to formation and do not requite the curing procedure. 

The separator must be stmcturaHy sound to withstand the rigors of battery manufacturing, and chemically inert to the lead—acid cell environment. Numerous materials have been used for separators ranging from wood, paper, and mbber to glass and plastic. The majority of separators used are either nonwoven—bound glass or microporous plastic such as PVC or polyethylene. 

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