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Information updated to: 31/08/2016

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Project

Nuovo processo a basso impatto ambientale ed a ridotto rischio operativo per il recupero ed il riciclo dei materiali costituenti le batterie al piombo

Code PON01_01366

Related training project

Description
Beneficiaries
Objectives

Results

Field/s	Environment and Ecology
Description	Industrial processes for the recycling of exhausted lead batteries actually in use are carried out by a crashing at random which leads to a mixing and consequently to a non-differentiation of the various parts of the battery. After this mechanical pre-treatment the following operations consist of a coarse separation of the different phases in function of their density and dimensions which permit the separation of the plastics from plumbiferous materials. The lead and lead compounds (battery paste consisting in lead oxides and sulfates) separated are treated in a rotary furnaces in which lead is melted and successively the lead compounds are reduced by carbon oxide at temperatures higher than 1300° C. Sometimes the battery paste is desulphurized by treatment with sodium carbonate in aqueous solution. In this case, the reducing process in the rotary furnace can be carried out at lower temperatures (1000°C). Anyway, this process permits only a limited recovery of the lead, not more than 80%, and therefore, creates environmental problems for the disposal of the slag. Furthermore the gaseous emissions coming from the furnace create serious environmental problems for which is necessary a continuous control to avoid the overcame of the permitted law limits. The lead obtained does not have yet commercial quality, it can be classified as a bullion and has to be thermal refined (with further notable increases of the energetic costs). The new technology is based on the statement that the single component of the battery maintain, during their life cycle, the chemical purity of the raw material used for the construction of a new battery. The new process , carried out under 500°C, already proved at the lab scale, consists in the separation, avoiding cross-contamination, of the single parts of the battery and in their separated treatment, in order to re-use the parts, directly or after simple processes, in the production of new batteries. In this way it is possible to reduce drastically the energetic consumption, to eliminate the production of slag and the harmful gas emissions and, consequently to increase the recovery yield. Synthetically : - the grids in lead/calcium alloy and the parts in lead/antimony alloy will be melted separately in order to obtain the original materials for the batteries without any ulterior intermediate refining process; - the battery paste will be converted, by chemical treatments, in lead oxide recyclable submicronic powder; - the acid electrolyte will be regenerated and concentrated by membrane technology; - the polypropylene of the external housing will be recovered as plastic to be recycled; - the polyethylene spacers will be used as raw material in pyrogasification processes to produce gas fuel. The human exposure to a dangerous working environment is drastically reduced by the use of an extensive use of automation and robotization allowed in this new technology.
Total cost	6,648,928.95 euro
Public contribution		Total public contribution 5,197,000.36 euro NOP R&C contribution 4,646,803.86 euro PAC contribution 0.00 euro Contribution from other funds 550,196.50 euro
Distribution	Advancement of distribution in %	Total amount distributed 3,771,370.42 euro NOP R&C distributed amount 3,653,560.42 euro PAC distributed amount 0.00 euro Amount distributed with other funds 117,810.00 euro

Legend

Field/s – Indicates the field or fields in which the project has the most relevance. A project may have more than one field. For some projects it is not assigned. The field are the following 8: "Health and wellbeing", "Food", "Energy", "Environment and Ecology", "Transport and Logistics", "Cultural goods and activities", "Social Innovation" and "Smart Cities".

Description – Descriptive summary of project.

Total cost – Total cost of project.

Public contribution – Three elements are reported:

Total commitment – total amount admitted to financing, may include more than contribution to be valued on NOP R&C, also on other funds.
NOP R&C admitted contribution
PAC admitted contribution
Contribution with other funds

Distribution – The following elements are reported:

Total distributed amount – takes into account the distributed amount considering both NOP R&C distribution and other funds if provided for
NOP R&C distributed amount – amount distributed to financing of project to be valued on NOP R&C
PAC distributed amount – amount distributed to financing of project to be valued on PAC
Amount distributed with other funds – amount distributed to financing of project with other funds

The distributions refer to the date of last update indicated at top.

Type of beneficiary

Public commitment for beneficiary

Medium business	1
Public research organisation	1
University	2
Micro business	1
Total Beneficiaries	5

IBF SpA

Tax File Number: 02267330716
Unique Project Code: B71H11000400005
Location of financial commitments: Puglia

Type: Medium business

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Presentation date	09/04/2010
Approval date	11/12/2015
Start of activity	Expected date 01/12/2011	Effective date 01/12/2011
End of activity	Expected date 31/12/2015	Effective date -
Total cost	464,063.97 euro
Public contribution	Total 279,144.83 euro	Eligible of NOP R&C 279,144.83 euro
Distribution	Total -	Amount of NOP R&C - Date of last distribution of NOP R&C -

CNR - Consiglio nazionale delle ricerche

Tax File Number: 80054330586
Unique Project Code: B61H11001520005
Location of financial commitments: Non disponibile

Type: Public research organisation

See beneficiary profile >

Presentation date	09/04/2010
Approval date	11/12/2015
Start of activity	Expected date 01/12/2011	Effective date 01/12/2011
End of activity	Expected date 31/12/2015	Effective date -
Total cost	1,523,086.76 euro
Public contribution	Total 1,294,623.74 euro	Eligible of NOP R&C 744,427.24 euro
Distribution	Total 804,609.15 euro	Amount of NOP R&C 686,799.15 euro Date of last distribution of NOP R&C -

Politecnico di Bari

Tax File Number: 93051590722
Unique Project Code: B51H11000950005
Location of financial commitments: Puglia

Type: University

See beneficiary profile >

Presentation date	09/04/2010
Approval date	11/12/2015
Start of activity	Expected date 01/12/2011	Effective date 01/12/2011
End of activity	Expected date 31/12/2015	Effective date -
Total cost	1,725,000.00 euro
Public contribution	Total 1,466,250.00 euro	Eligible of NOP R&C 1,466,250.00 euro
Distribution	Total 1,466,250.00 euro	Amount of NOP R&C 1,466,250.00 euro Date of last distribution of NOP R&C -

STC srl - Science Technology & Consulting

Tax File Number: 02441980782
Unique Project Code: B21H11000330005
Location of financial commitments: Non disponibile

Type: Micro business

See beneficiary profile >

Presentation date	09/04/2010
Approval date	11/12/2015
Start of activity	Expected date 01/12/2011	Effective date 01/12/2011
End of activity	Expected date 31/12/2015	Effective date -
Total cost	2,421,778.22 euro
Public contribution	Total 1,719,231.79 euro	Eligible of NOP R&C 1,719,231.79 euro
Distribution	Total 1,062,761.27 euro	Amount of NOP R&C 1,062,761.27 euro Date of last distribution of NOP R&C -

Università della Calabria

Tax File Number: 80003950781
Unique Project Code: B11H11000320005
Location of financial commitments: Calabria

Type: University

See beneficiary profile >

Presentation date	09/04/2010
Approval date	11/12/2015
Start of activity	Expected date 01/12/2011	Effective date 01/12/2011
End of activity	Expected date 31/12/2015	Effective date -
Total cost	515,000.00 euro
Public contribution	Total 437,750.00 euro	Eligible of NOP R&C 437,750.00 euro
Distribution	Total 437,750.00 euro	Amount of NOP R&C 437,750.00 euro Date of last distribution of NOP R&C -

Axis - Operational objective	I - Scientific and technological fields, generators of industry transformation processes and creators of new sectors (Go to )
Action	Strategic scientific and technological areas
Action line	Industrial Research (Go to)
Instrument of implementation	Invitation to presentation of Industrial Research projects (DD 1/Ric 18/01/10)
NSF - objective	Strengthen and evaluate the whole chain of research and cooperation networks between the research system and businesses, to contribute to competitiveness and economic growth; sustain maximum distribution and use of new technologies and advanced services; heighten level of scientific and technical knowledge and skills in the production system and in institutions