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Title page 1

Contents 3

Abstract 1

Abbreviations 5

Foreword 6

1. Introduction 9

1.1. Background 9

1.2. Scope, methods, & objectives 10

2. Current end-of-life management of lead-acid batteries 11

2.1. Collection 11

2.2. Repair & reuse 11

2.3. Recycling 12

2.3.1. Battery breaking 14

2.3.2. Lead smelting 14

2.3.3. Lead refining 16

2.3.4. Management of battery electrolyte 18

2.3.5. Off-gas treatment 19

2.3.6. Recycling of plastic cases 19

2.3.7. Management of slags 19

2.3.8. Housekeeping & dust control 21

2.3.9. Safety 23

2.3.10. Industrial hygiene 24

2.4. Policy framework, licensing, & monitoring 26

3. Economics of different lead-acid battery recycling patterns 28

3.1. Investment costs 28

3.2. Total cost structure 30

4. Summary and policy implications 33

5. Bibliography 39

Tables 4

TABLE 1. Indicative data on slag generation in different plant setups 21

TABLE 2. Estimated investment costs for a high-standard medium-sized plant (10,000-20,000 mt/a lead output) 29

TABLE 3. Estimated investment costs for a low-standard medium-sized plant (10,000-20,000 mt/a lead output) 30

TABLE 4. Comparison of cost structures of high- and low-standard industrial ULAB recycling plants 32

Figures 4

FIGURE 1. Geographic overview of industrial ULAB recycling plants in Ogun State, Nigeria 13

FIGURE 2. Battery breaking as commonly conducted in industrial ULAB recycling plants in sub-Saharan Africa 14

FIGURE 3. Furnace types used for secondary lead smelting in sub-Saharan Africa 15

FIGURE 4. Substandard refining kettle as frequently observed in ULAB recycling plants in sub-Saharan Africa 17

FIGURE 5. Battery breaking area with no functional system to capture electrolyte 18

FIGURE 6. Unsound management of slags as commonly observed in and around ULAB recycling plants in sub-Saharan Africa 20

FIGURE 7. Characteristic situations linked to housekeeping and dust control in ULAB recycling plants in sub-Saharan Africa 22

FIGURE 8. Symptoms of underdeveloped safety culture as observed in many ULAB recycling plants in sub-Saharan Africa 24

FIGURE 9. Typical washroom amenities as observed in ULAB recycling plants in sub-Saharan Africa 26