Batteries are an important part of our daily lives at home, work, or play. We depend on batteries for communication (cell phones) and transportation (cars, hybrids, EVs, and golf carts), and the list goes on and on. As useful as batteries are, though, they do have a lifespan.

When batteries are used up, we have a legal and ethical responsibility to recycle them for the good of the environment and the public health. Batteries are generally safe to use, but do contain toxic chemicals and need to be handled and disposed of properly.

Batteries are Booming

The demand for UPS battery systems has seen strong growth as computer systems, network applications, and a host of other processes expand for small and large companies. Batteries are also a key component of green initiatives with hybrid and electric cars, as well as solar power. This growth in battery applications necessitates a commensurate increase in recycling to conserve limited resources, protect the environment, and mitigate health risks to the public.

EPA Enforcement

The EPA enforced “Battery Act” was signed into law on May 13, 1996 and requires efficient and cost-effective collection and recycling (or proper disposal) of used batteries. The battery industry has been responsive in complying with the mandates. UPS battery manufacturers such as Enersys, East Penn Manufacturing (Deka), and C & D Technologies operate, or are affiliated with, EPA-compliant battery recycling programs.

Lead-Acid Accolades

It is estimated that over 90 percent of a lead-acid battery can be recycled. The main components of a battery are plastic, lead, and sulfuric acid. The plastic battery enclosure is broken apart and melted down. The molten plastic is processed into small plastic pellets that are used to make new battery cases, and the process begins again.

The lead components of a lead-acid battery are heated at high temperatures during recycling. The molten lead is then poured into ingot molds. Battery manufacturers then re-melt and use in the production of new batteries. In the USA, recycled batteries provide over 50 percent of the lead supply.

The sulfuric battery acid is neutralized with an industrial compound similar to household baking soda. This turns the battery acid into water, which is then treated, cleaned, and tested to meet clean water standards. Acid can also be converted into sodium sulfate, an odorless white powder that is used in laundry detergent, glass, and textile manufacturing.

Recycling Newcomers

Although the recycling process for lead-acid batteries is well established, the same cannot be said for the lithium-ion and nickel cadmium batteries that power electric and hybrid vehicles. Since these types of batteries are relatively new to the market, recycling is still in its infancy. A few recycling companies already have the capacity to recycle NiCad and Li-Ion batteries, but demand will only rise as the market matures.

Nickel Cadmium (NiCad): Nickel cadmium battery recycling requires the recovery of the valuable nickel components and the capture of all other hazardous elements. NiCad batteries are heated to a temperature that enables the recovery of cadmium and the removal of other battery materials. This process creates cadmium ingots that are used in the production of new batteries, as well as a nickel-enriched iron composite that can be reused in many applications, including stainless steel production.

Lithium-Ion: Lithium-ion batteries are shredded so that the metal components, like copper and steel, can be easily sorted out. If the batteries still have a charge, they are frozen in liquid nitrogen (so they cannot react) and are safely shredded. These batteries contain only a small fraction of lithium carbonate, and the average lithium cost associated with Li-ion battery production is less than 3%. Thus, the value for the Li-ion recycling business currently comes from valuable metals, such as cobalt and nickel, that are more highly priced than lithium.

Remember to Recycle

Batteries are an important part of modern life, but they are made of non-renewable resources and toxic chemicals. Recycling batteries helps conserve valuable non-renewable resources and also provides for the safe handling of toxic chemicals that could otherwise harm the environment and/or cause serious health risks. The “Battery Act” was signed into law for this very purpose, and we must remember to adhere to it for the greater good.