Electric car batteries: Avoiding the environmental drawbacks via alternative technologies

In this article, we address the question of whether air pollution resulting from the pyrometallurgical winning, recycling, and casting of lead for car batteries is a serious threat to the environmental acceptability of introducing electric cars. Specifically, we describe an alternative to pyrometallurgical processes—an electrochemical process called CX-EWS that can be used for the winning and recycling of lead. Also presented is a new manufacturing route for battery grids; it employs a combination of electroforming, the codeposition of dispersoids, and the electrowinning of spent batteries. The technology cannot only eliminate the casting of conventional or expanded metal grids but can also serve to reduce battery weight and, thus, increase energy density.