CASE STUDY # 115
1. Headline: Automation of battery plate manufacturing
process reduces lead oxide dust by 85% and wastewater by
98%.
2. Background: See below.
3. Cleaner production Principle: new technology
4. Description of Cleaner Production Application: This audit
of a manufacturer of battery plates suggests that the
automation of the mold filling stage, reduces waste
generation. Battery plates are placed manually in a fixed
mold which is located in a sound-proof cabinet. When the
cabinet is closed, the mold is automatically filled with
lead powder. This process is quite different from the
standard technology where the battery plates are placed in
mobile molds which are manually handled and filled with
lead oxide powder. These operations are conducted under
water spraying in order to reduce dust. Polluted air is
extracted.
Material/Energy Balance and Substitution
FEEDSTOCKS: Lead
oxide powder, water
WASTES: Lead
oxide dust; water containing lead
dust
MEDIUM: Aqueous,
air
5. Economies
COST: (For
230,000 battery plates produced
per year)
CAPITAL COST: FF
1,500,000 (1979 figures)
OPERATION/MAINTENANCE: FF
7,730,000 (1979 figures)
MONTHS TO RECOVER: Not reported
DISPOSAL & FEEDSTOCK: FF
565,000 (1979 figures)
6. Advantages
FEEDSTOCK REDUCTION: Material consumption is 2.4 tons of
lead oxide and 2 m3 of water per 1,000 battery plates
(versus 2.6 tons of lead oxide and 80 m3 of water per
1,000 battery plates with the standard technology).
WASTE PRODUCTION: Manufacture of 1,000 battery plates
generates 110 g of lead oxide dust (including 16 g of
lead) and 2 m3 of water containing lead dust (versus 830 g
of lead dust, 380 g of lead and 80 m3 of water in the
standard technology).
IMPACT/PROBLEMS: The quantity of water used is
substantially reduced, improving reliability and
efficiency. Substantial improvement of working
conditions: elimination of one night shift; reduction of
operator fatigue, and the noise level goes down from 95 dB
(standard technology) to 85 dB (low-waste technology).
7. Constraints: No information provided.
8. Contact and Citation:
Compendium on Low and Non-waste Technology, United Nations
Economic and Social Counsel, "Production of Lead Battery
Plates by Automatic Filling of Fixed Molds", Monograph
ENV/WP.2/5/Add.70
9. Keywords: France, battery, battery plate, new technology,
lead, water saving, ISIC 3800.
10. Reviewers Comments: This case study was originally
abstracted for the US EPA Pollution Prevention Information
Clearinghouse. It underwent a UNEP IE funded technical
review in 1994 for quality and completeness. It was edited
for the ICPIC diskette in July 1995.
( DOCNO: 400-070-A-307 )