Battery cases, recycling

PP-battery cases recyclates, processing stability.VV from battery cases is commercial reclaimed and re-used. In the 1994, in U.S.A. about 100,000 ton, and in Western Europ> around 43,000 recovery. Figure 10 shows the processing behavior of PP recyclate fron the battery cases. 

L PP Battery cases recyclate, long term thermal stability... 

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). 

Eew of the products in which polypropylene are used can be recovered in commercial quaUties. An exception is battery casings. In 1994, U.S. capacity for recycling polypropylene from battery casings was 265 million pounds aimuaHy (45). About 75% of the recovered polypropylene is used in new battery cases which have a recycled PP content of about 50%. Total polypropylene recycling capacity was 350 million pounds aimuaHy for an operating rate estimated at 71—90% (45). 

Prior to smelting, batteries are usually broken up and sorted into their constituent products. Fractions of cleaned plastic (such as polypropylene) case are recycled into battery cases or other products. The dilute sulfuric acid is either neutralized for disposal or recycled to the local acid market. One of the three main smelting processes is then used to reduce the lead fractions and produce lead bullion. 

Total recycled thermoplastic resin production almost tripled between 1990 and 1995 and is well over 1 billion lb per year. The percentage breakdown of the amount for recycling is the following HDPE (especially bottles), 35% PET (soft drink bottles), 34% PP (auto battery cases), 14% LDPE (film), 9% PS (packaging), 3% PVC, 0.5% other, 4%. 

A related situation we ll call piggyback markets. By this we mean industries in which extensive recycling exists for some material other than polymers, but in which polymers are easily separated for recycle as well. We earlier mentioned the recycling of polypropylene battery cases. Infrastructure was already in place to recover valuable lead metal from the electrodes. It was easy to also recover the plastic cases when polymer recycling became feasible. Table 9-3 summarizes a few examples. 

Among the polypropylene products, the most recycled are the battery cases. Almost all automotive and truck battery cases are made of PP, and there is a well-established industry to recycle batteries in the United States, due to its lead contamination. Because of the combination of land disposal ban, and mandated delivery/take-back provisions, automotive batteries are recycled at a very high level. About 40 percent of the recovered PP is used again in battery production and the rest is used for making other injection-molded products. Some of the cleaner recycled PP can be used in libers, such as spunbond or meltblown nonwovens for geotextiles or filter applications. ... 

The major challenge to all recovery systems will be the increasing level of other plastic types in the feed material. Materials such as ABS (acrylonitrile butadiene styrene) are being used in VRLA battery cases, due to their toughness and rigidity relative to traditional polypropylene. For the recycler, this means that the valuable polypropylene tonnage will fall with a reciprocal increase in plastic types that cannot be recycled. This material will have to be disposed of, as ABS and... 

Washed and dried polypropylene pieces are sent to a plastic recycler, where the chips are melted [12] and extruded to produce plastic pellets for use in the manufacture of battery cases and other plastic components. Great care must be taken to ensure that the mechanical breaker cleans the polypropylene chips free of any residual oxide, because subsequent handling of the chips by operating personnel, especially at the plastic recycling plant, can result in significant levels of lead exposure. Should the wash sprays on the breaker fail to remove all traces of battery paste, consideration should be given to further washing with a dilute sodium hydroxide solution. 

Used lead-acid automobile batteries represent a major hazard to the environment. Most landfills accept batteries but place them aside for recycling, which includes collecting and neutralizing the acid, removing the cases, and resmelting the lead plates. Fragments of cases can be recycled into new battery cases, and resmelted lead is used to cast new battery plates. In New Zealand alone, 500,000 lead-acid storage batteries are recycled each year. 

Subam was the first manufacturer to offer fuUy recyclable PP/TPE bumpers for all car models. To recycle, the bumpers are chopped into sections and placed between rollers rotating at different speeds. This removes 99% of paints and coatings. The sections are then re-stabihzed and granulated, ready for re-use. Similarly, Nissan aims for 100% bumper-to-bumper recycling of PPE/PA. Fiat has a policy of 100% recycling its TPO bumpers into automotive parts that do not demand similar level of performance, viz. air ducts, liners, etc. The PP battery cases are being recycled as fender liners. 

Recyclostab , containing antioxidants and costabilizers, viz. Recyclostab 411 or 421, based on phenol, phosphite antioxidants and suitable co-stabilizer, designed for PO or PET recycling. Recyclostab 451 has been successfully used for recycling PP battery cases by injection molding. 

PP battery cases (95% recycled) battery cases Anonym., 1996b... 

It may be noted that a substantial fraction of the lead in spent lead-acid batteries is recycled and not discarded. In the United States, about 95% of the lead used in lead-acid batteries is recycled (1989) and similar figures are likely to apply to other industrialized countries, if not now, then soon. In the case of Ni/Cd batteries, a smaller fraction is recycled, but that situation is likely to improve as more recycling facilities come on stream. The battery industry has made a concerted and relatively successful effort during the past decade to eliminate mercury from their products, and, in combination with mercury recycling, these efforts may be expected to significantly reduce the addition of mercury from batteries to communal waste streams. It becomes clear that the battery contributions to the overall problem is a matter of concern. The solution of the public health problem needs to be approached as a whole by extending the required treatments to cover all the sources of these public pollutants. 

Because the casing makes up about 7% of the total battery and the used batteries are recycled primarily for lead recovery, PP is obtained without additional cost and in substantial quantities to warrant the operation of a plastics recycling plant. 

By contrast, relatively uncontaminated single polymer types can be collected from retail outlets by segregation on site [e.g. discarded polypropylene crates, battery cases and supermarket shrink-wrap). These can be recycled with the addition of new antioxidants and UV stabilisers into the primary application, generally as a blend with virgin polymer, without significant loss of mechanical properties. 

Automobile batteries have also been designed for recycling. The secme case permits return of the failed battery to the recycler without unique environmental problems. Lead recyclers have developed processes to recover virtually all the lead values in the battery for return to new battery production, hi addition, the battery cases and acid have been also recycled to usable products. Lead acid batteries represent the highest recycling rate of any commercial product. Rates of 95-97% have been achieved in the late 1990 s. 

Concept - recyclable polyester headliner A pillar 100% recycled ABS plastic Battery spacer 100% recycl battery cases... 

Other Deposit Systems. The idea behind beverage bottle deposits has also been apphed to other products. Automobile batteries are subject to deposits in many states. While the primary motivation is to avoid the introduction of lead into landfills and incinerators, these systems have been very successful at facilitating the recycling of the polypropylene (PP) battery cases. Deposits are also common on tires. 

Lead-acid batteries are prohibited from MSW disposal facilities in 37 U.S. states, primarily due to concern about the effects of lead. Several states impose deposits on batteries. Effective recycling programs for these batteries have existed for a number of years. The Battery Council International reports a 2003 recycling rate of more than 97 percent for lead-acid batteries. Polypropylene makes up about 7 percent of the battery, by weight, and is recovered along with the lead. The primary market for the recovered PP is new battery cases. A typical battery contains 60 to 80 percent recycled PP. The recycling rate for the cases can be assumed similar to that for batteries. ... 

A relatively small amount of plastic is recycled on an annual basis in comparison to the production levels of plastic resins or the amount disposed in MSW landfills. It has been estimated that 340-400 million pounds of plastics were recovered or recycled in some fashion in 1989. Approximately 29 billion pounds were disposed in MSW. About half of tlie recycled plastic came from the recycling of PET beverage bottles (including the HOPE base cup on such bottles), and most of the remainder came from HOPE bottles, PET x-ray film and PP car battery cases. The amount of plastics recycled in comparison to the amount disposed is 1.3%, and in comparison to the annual production level of plastics in the U.S. is 0.6%. A review of the 15 primary resins produced in the U.S. shows that five of the above mentioned resins are disposed of primarily through MSW, and that the remtiining plastics are generally destined for non-MSW disposal, i.e. 

The primary components of recycled plastics were as follows 160 million lbs. PET soda bottles, 100 million lbs. HDPE, including 40 million lbs. of soda botUe base cups, 60 million lbs. PP car battery cases. 12 million lbs, PET X-ray film and 10 million lbs. all else [Schut, 1990]. 

Recycling of PP battery cases also takes place outside the United States. Germany began such recycling in 1984, yielding about 3000 tonnes/year of polypropylene. The process involves crushing the batteries... 

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