INTERNATIONAL CLEANER PRODUCTION INFORMATION CLEARINGHOUSE

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 )