The manufacturing steps include: grid manufacturing, paste manufacturing, plate manufacturing, plastic molding, and assembly. Of the 31 MJ of energy typically consumed in the production of a kilogram of lead–acid battery, about 9.2 MJ (30%) is associated with the manufacturing process.
The main components of the lead–acid battery are listed in Table 13.1. It is estimated that the materials used are re-cycled at a rate of about 95%. A typical new battery contains 60–80% recycled lead and plastic (Battery Council International 2010). There appears to be no shortage of lead, as shown in Table 13.3. TABLE 13.3.
Although lead acid batteries are an ancient energy storage technology, they will remain essential for the global rechargeable batteries markets, possessing advantages in cost-effectiveness and recycling ability.
Of the 31 MJ of energy typically consumed in the production of a kilogram of lead–acid battery, about 9.2 MJ (30%) is associated with the manufacturing process. The balance is accounted for in materials production and recycling.
The fundamental elements of the lead–acid battery were set in place over 150 years ago. In 1859, Gaston Planté was the first to report that a useful discharge current could be drawn from a pair of lead plates that had been immersed in sulfuric acid and subjected to a charging current, see Figure 13.1.
Currently, stationary energy-storage only accounts for a tiny fraction of the total sales of lead–acid batteries. Indeed the total installed capacity for stationary applications of lead–acid in 2010 (35 MW) was dwarfed by the installed capacity of sodium–sulfur batteries (315 MW), see Figure 13.13.