Pure Environmental takes on battery recycling

May 06, 2023

Pure Environmental is breaking the mould when it comes to battery recycling, with a new state-of-the-art facility in Victoria.

The world is undergoing one of the most significant energy transformations in history with the transition to renewables, says Dr Karl Baltpurvins, Chief Executive Officer for Pure Environmental.

To support this transition, he says society will need to adopt innovative means of storing energy, including batteries that will be used to power all manner of appliances and electric vehicles in the future.

Lead-acid is the oldest rechargeable battery in existence, invented by the French physician Gaston Planté in 1859. Lead-acid remains the dominant battery chemistry used in the world today and, Karl says, will continue to play a role in providing safe and cost-effective energy storage as other battery chemistries such as lithium and nickel-based systems are adopted.

He says those who forecast the demise of lead-acid batteries in favour of longer-lasting and faster-charging lithium-ion batteries, may have been too quick to judge.

Even with an increasing consumer uptake of electric vehicles, lead-acid batteries are commonly used to run the electrics because they are cheaper, have high temperature performance, a proven supply chain and recyclability.

That's where Pure Environmental come in.

Pure's vision is to transform the circular economy through advanced resource recovery. It specialises in the treatment of regulated waste types generated by a range of industry sectors.

As Karl explains, it's not a traditional waste management operation.

"We’re focused on waste processing rather than collection," he says. "We want to minimise the environmental impact of regulated waste.

"Recycling of used lead acid batteries (ULAB) is a good story. We can recover 98 per cent of a battery. The resources are regenerated, rejuvenated, and turned back into a new product.

"We’re closing the loop with an onshore solution."

Pure Environmental's investment in Nexus, a battery breaking facility in Western Australia, does just that. Nexus is licensed to process about 30,000 tonnes of ULAB per annum – more than the entire number of used lead acid batteries generated in Western Australia annually.

All components recovered are sent downstream to refiners and recyclers for recovery and reuse.

Pure Environmental is extending its reach to Victoria, constructing a fully automated, best-practice battery recycling facility in Hazelwood, Gippsland, to process and recover lead bullion.

Karl says the Hazelwood facility is waiting on construction approval and is aiming to process 50,000 tonnes per annum, when fully operational.

Recovered lead will be refined into high purity metals or bullion, filling a gap in the market.

"At the moment a portion of Australia's lead from ULABs is exported because there's not enough capacity to refine the lead grid and paste onshore," Karl says.

"We’re providing a solution that will provide that capacity and keep manufacturing within the La Trobe Valley and Australia."

Almost all components in ULABs can be separated and remanufactured. The recycling process involves breaking down the batteries and recovering parts for reuse including metallic plates, plastics, lead paste and acid electrolyte.

The lead can be melted down and made into ingots and used to make new batteries or other construction and industrial products. Plastics from the casing can be made into pellets and reused in manufacturing.

Karl says ULABs are a tradeable commodity and will continue to be for some time.

"There is a perception that lead acid batteries are on the way out because of electric vehicles, but that's not the case," he says.

"ULABs are still relatively low-cost compared to other batteries. They offer a more economical and reliable alternative in back-up situations where weight and recharge time are not limiting factors. Combined with the supply shortage of lithium-ion batteries, lead acid batteries are being seen as part of the solution."

The Pure Hazelwood facility will have ultra-low emissions, high recovery and best practice technology based on what is being used by one of the world's largest lead-acid battery recyclers.

Karl says they’re aiming to reduce greenhouse gas emissions by 34,937 tonnes per annum – the equivalent to removing 8000 internal combustion engine cars from the road each year.

"We’re very socially oriented," he says. "Our work practices are focused on environmental and social governance. We want the plant to exceed environmental best practice and provide another solution for the recycling of lead acid batteries in Australia."

For more information, visit: www.purenv.com.au

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