Awaiting Public Project Summary

"Lead Acid Batteries (LABs) are a vital and widely-used technology. Invented in 1859, LABs are the most mature rechargeable battery technology available, making up half the global demand for rechargeable batteries. To meet recycling targets, in developed economies, the lead metal from waste LABs is smelted in furnaces at 1,100C. This energy intensive ""pyrometallurgical"" process is highly polluting and only economically viable at large-scale, resulting in hazardous waste shipment across borders. In developing countries, lead is recycled at very small scale, using crude, open furnaces, which is hazardous to human health and the environment. Globally, 26 million people are at risk of lead poisoning, with diseases leading to the loss of 9 million Disability Adjusted Life Years. The major cause of lead poisoning is unsafe battery recycling. The University of Cambridge has invented a new ""hydrometallurgical"" process that is highly energy efficient, clean, scalable and cost effective. Aurelius Environmental has the exclusive license to exploit this novel technology, ""NUOVOpb"", globally. NUOVOpb reduces the carbon footprint of LAB recycling by up to 89%, eliminates SOx and NOx pollutants, and is economically viable even at small scale (1,000 tonnes/yr). Crucially, it produces lead oxide directly (normally produced through a secondary process), and the unique nano crystalline structure of this lead oxide improves the energy density in new LABs by 30% and provides a 50% longer life. NUOVOpb will transform the growing, global battery recycling industry, which has an expected value of £8 billion in 2024\. The huge market opportunity for NUOVOpb is, however, restricted by the cost and availability of the primary reagent used. This project will develop reagent substitutes to enable us to meet global demand for our technology, contribute to sustainability and growing our business."

With a growing urban population and people becoming wealthier, Brazil is seriously facing the challenge to meet increasing energy demands through efficient, eco-friendly and cost-effective approaches. According to the International Energy Agency, Brazil will experience an 80% increase in its energy demands by 2035. Though new cell chemistries are being developed (such as high energy density and lightweight Lithium Ion batteries), lead-acid batteries (LABs) remain the most economical battery technology for almost all industrial and commercial applications. Only the automotive sector will generate a demand for almost 30 million LABs/year by 2020 in Brazil. Developed by UK-based Aurelius Environmental, NUOVOpb is a novel, low-cost, scalable and eco-friendly LAB recycling processes based on “hydrometallurgy”, meaning it uses low temperature and aqueous citric acid solutions to recycle lead and lead oxide rather than burning the metal at extremely high temperatures (>1,100°C) as done in “pyrometallurgy”. Combined with our Brazilian partner’s novel sulphuric acid processing technology, this project will develop a truly complete LAB recycling system. Current pyrometallurgical recycling practices produce high levels of toxic gases (SOx, NOx) which damage workers’ health. According to Green Cross, pyrometallurgical LAB recycling is the worst polluting industry in developing countries by disability-adjusted life years. By replacing pyrometallurgical recycling with NUOVOpb’s water-based recycling process, we avoid the emission of noxious gases and therefore improve working conditions. Furthermore, smelting plants are only economically viable at large scale (~22,000 tonnes/yr) meaning few large smelters need to transport waste LABs. NUOVOpb is scalable at 1,000 tonnes which is crucial for low-volume recycling in Brazil and creates more job opportunities. This project therefore can alleviate poverty, improve employee working conditions, reduce the environmental impact from LAB recycling and bring substantial revenues for our project partners. 5 years post-project, we expect to be operating 10 NUOVOpb plants in Brazil through our partners’ commercial agreement. Through NUOVOpb, we will reduce CO2 emissions by up to 89%, meaning we will cumulatively save approximately 96,000 tonnes of CO2. Total energy savings could add up to 288 GWh, the equivalent of the energy capacity of 96,000 3MW wind turbines. We will also help protect human health especially of children who are most vulnerable to the toxic effects of pyrometallurgy and create jobs, in particular in remote areas in Brazil where pyrometallurgy is not economically viable. By launching NUOVOpb in Brazil we aim to substantially increase current lead recycling rates, reaching similar levels in developed countries.