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The importnat difference between two types of batteries is that the chemical reaction is reversible with a rechargeable battery: when electrical energy from an external source (a charger) is applied to the battery’s secondary cell, the negative-to-positive electron flow that occurs during discharge gets reversed. As this happens, the cell’s charge gets restored. While Single-Use batteries have no such option
Major components of a Single-Use Batteries include ...
Annode is also known as the positively charged electrode by which the electrons leave a device
Zinc powder is a bluish-gray colored, pure metal powder. It is produced when purified vapors of zinc are condensed. Some of its characteristics are consistent quality, improved yields and quick reaction time. Zinc powder is utilized for many different purposes in various fields. It's important to learn more about this substance in order to take advantage of its many benefits and uses.
Zinc ores are dug from underground mines using conventional blasting, drilling, and hauling techniques. The ores occur as zinc sulfide (also called sphalerite), zinc carbonate (smithsonite), zinc silicate (calimine), and in compounds of manganese and iron (franklinite). Zinc ore is sometimes mined in conjunction with silver or lead ores. In addition to the ore itself, oil and sulfuric acid are required for the breakdown of the ores; and electricity, coke, or natural gas are needed to provide the heat energy for smelting.
Zinc can be produced by a process called froth flotation, which is also used for reduction of copper and lead ores. This process involves grinding the zinc ore to a fine powder, mixing it with water, pine oil, and flotation chemicals, and then agitating the mixture to "float" the zinc to the surface. A variety of chemicals are used to coat the important zinc particles and prevent them from becoming wetted by the water. Then air is injected, and the coated minerals Zinc attach themselves to the bubbles.
Zinc powders and dusts are essentially finely divided zinc metal. A distinction is often made whereby ‘zinc dust’ refers to the product made by condensation of zinc vapor and ‘zinc powder’ to the product of atomization of molten zinc. However, since the difference between powder and dust is essentially a matter of fineness, dusts being finer – sometimes the terms ‘dust’ and ‘powder’ are used simply to differentiate fine or course materials.
•Either of the two zinc production and refining stages outweigh the mining and mineral processing.
• The Hydrometallurgical Process produces high levels of liquid waste and is more energy intensive. (‘An environmental assessment of lead and zinc production processes’ T E Norgate and W J Rankin)
• The production for sulfidic zinc ores produces large amounts of sulfur dioxide (can form acid rain) and cadmium vapour.
• Unwanted by-products from zinc production include sodium oxide (corrosive and violent when exposed to water) and carbon monoxide (toxic to humans and animals as well as ozone-forming) and carbon dioxide.
• The production of zinc produces around 3 tonnes of CO2 per tonne of zinc
Electrod is also known as a conductor through which electricity enters or leaves an object, substance, or region.
Brass is a metal composed primarily of copper and zinc. Copper is the main component, and brass is usually classified as a copper alloy.
Sometimes, Brass can be mistakenly percieved as gold due to the similarity in color.
Copper can be extracted from its ore by sinking a vertical shaft into the Earth to an appropriate depth and driving horizontal tunnels into the ore. Open pit: 90% of ore is mined by this method. Ores near the surface can be quarried after removal of the surface layers. The ore is treated with dilute sulfuric acid. This trickles slowly through the ore dissolving copper to form copper sulfate. The copper is recovered by electrolytic refining. It is important to remember that open pit mining is one of the most common ones that are used for mining copper.
Processing of copper is a long and extremely complicated process that involves 7 stages.
1) Crushing and gridning
2) Froth flotation
3) Roasting
4) Smelting with fluxes
5) Conversion of matte to copper blister
6) Anode casting
7) Electrolytic refining
It all happens due to fact that the ore from the mine contains only about 2% copper
The manufacturing process used to produce brass involves combining the appropriate raw materials into a molten metal, which is allowed to solidify. The shape and properties of the solidified metal are then altered through a series of carefully controlled operations to produce the desired brass stock.
Brass manufacturing similarly to copper production includes several steps.
1) Melting
2) Hot rolling
3) Annealing and cold rolling
4) Finish Rolling
* Brass production is a process that involves a large number of byproducts, toxins and etc. created during a production process. One of the main contributors is copper and copper production by itself is a long process with an enormous carbon footprint and higly contaminating toxic polution.
* It is also important to remmebre that the goal of mining is to end up with a mostly pure and usable element that can be utilized in whatever way necessary. However, the ores that are extracted from the earth do not come out pure, instead they need to undergo a refining process. This refining process introduces another set of environmental concerns, mostly revolving around the release of metal byproducts into the environment. It is very easy for metals to enter the air, ground, and once there it is nearly impossible to remove them. The metals in an environment can also prove devastating to organisms.
Also known as the negatively charged electrode by which electrons enter an electrical device.
The mineral graphite /ˈɡræfaɪt/ is one of the allotropes of carbon. It was named by Abraham Gottlob Werner in 1789 from the Ancient Greek (graphō), "to draw/write", for its use in pencils, where it is commonly called lead (not to be confused with the metallic element lead). Unlike diamond (another carbon allotrope), graphite is an electrical conductor, a semimetal. It is, consequently, useful in such applications as arc lamp electrodes. Graphite is the most stable form of carbon under standard conditions.
Graphite extraction
* Open pit mining, where material is excavated from an open pit, is one of the most common forms of mining for strategic minerals.This method of mining, even when it is very much regulated by govt norms, poses serious danger on the surrounding environment.
* One of the main negative eefects of pit mining are:
1)Air pollution/ Presence of dust:
2)Sound Pollution
3)Ground Vibration
4)Water Pollution
5)Loss of forest and ecology
6) Resettlement
7)Loss of soil fertility
* In addition to that, there is also a gigantic carbon footprint left after transportation stage of this process is compleat and then furthere procces starts.
How do one of the most importan components of Lithium Ion battery come togehter and where everything appers?
For decades, commercial lithium production relied upon mineral ore sources such as spodumene, petalite and lepidolite. Extracting lithium from such sources, however, is significantly more costly than extracting the metal from lithium-containing brines. In fact, it is estimated that the cost of extracting lithium from hard rock is double that of producing from brines, explaining why most such sources have been priced out of the market over the past 20 years.
* In order to extract lithium from brines, the salt-rich waters must first be pumped to the surface into a series of evaporation ponds where solar evaporation occurs over a number of months. Because salar brines naturally occur at high altitudes and in areas of low rainfall, solar evaporation is an ideal and cost-effective method for precipitating salts
*Potassium is often first harvested from early ponds, while later ponds have increasingly high concentrations of lithium. Economical lithium-source brines normally contain anywhere from a few hundred parts per million of lithium to upwards of 7000ppm.
* The present invention relates to a process for producing lithium-cobalt oxide represented by the formula: Lix CoO2 (0<x<1), and more particularly, to a process for producing lithium-cobalt oxide particles represented by the formula: Lix CoO2 (0<x<1), useful especially as a cathode active substance for lithium ion batteries, which can be produced by calcination in a short time, and has a narrow particle size distribution and a uniform small particle size.
Lithium extraction and Lithium Cobalt Oxide production has a negative impact on the environment as well as all other components of a Li-On battery. At first, all components of Lithium Cobalt Oxide are being mined in an open pit manner which involves transportation that generates an enormous carbon footprint. Lithium Cobalt Oxide production itself generates quite a few toxic byproducts that are being dumped into water sources quite often.
*Aluminum foil is made from an aluminum alloy which contains between 92 and 99 percent aluminum. Usually between 0.00017 and 0.0059 inches thick, foil is produced in many widths and strengths for literally hundreds of applications.
*Aluminum foil is inexpensive, durable, non-toxic, and greaseproof. In addition, it resists chemical attack and provides excellent electrical and non-magnetic shielding.
Bauxite is usually covered by an overburden of several meters of rock and clay, which must be removed before the bauxite can be recovered.
Then, the bauxite is transported to crushing or washing plants, before it is transported for processing.
The clay is then usually deposited in tailing ponds. After its use, these tailing ponds are replanted using local species to re-establish natural vegetation.
*Aluminium is the most abundant metal on Earth. Despite this, it is expensive, largely because of the amount of electricity used up in the extraction process.
*Aluminium ore is called bauxite. The bauxite is purified to yield a white powder, aluminium oxide, from which aluminium can be extracted.
*The extraction is done by electrolysis. But first the aluminium oxide must be made molten so that electricity can pass through it. Aluminium oxide has a very high melting point (over 2,000°C), so it would be expensive to melt it. Instead, it is dissolved in molten cryolite, an aluminium compound with a lower melting point than aluminium oxide. The use of cryolite reduces some of the energy costs involved in extracting aluminium.
Aluminum foil manufacturing process involves few extra stages after aluminum is beeing refined. Next stage include smelting, and only when foil stocks are created rolling stage begins. At the end of rolling stage, as the foil sheets come through the rollers, they are trimmed and slitted with circular or razor-like knives installed on the roll mill. Trimming refers to the edges of the foil, while slitting involves cutting the foil into several sheets
* High levels of CO2 emmision
* Bauxite mining can cause: change of landscape and impact on biodiversity, removal and re-establishment of vegetation, disturbance of hydrology – the movement, quality and distribution of water.
* Toxic waste generation and disposal
Creation of copper foil involves the same process of mining and refining as for a regular copper. However, a production of copper foil is energy demanding.
After refining, the copper cathodes are melted and cast into ingots, cakes, billets, or rods depending on the final application. Ingots are rectangular or trapezoidal bricks, which are remelted along with other metals to make brass and bronze products. Cakes are rectangular slabs about 8 in (20 cm) thick and up to 28 ft (8.5 m) long. They are rolled to make copper plate, strip, sheet, and foil products.
* Manufacturing of electrolytic copper foil is started with the process of electrodepositing copper to a rolling drum and rolling it up. In this process, according to the condition of electrolysis, raw foils which have mechanical features suited to each purpose from general printed contributing boards to high functional digital equipment are manufactured. According to the purposes, raw materials of different mechanical features from 6 µm to 175 µm are manufactured
*Copper foil is widely responsible to features required to various electronic devices such as one surface and both surfaces roughening processing, fine roughening processing and black processing foils. To clear various types of reliability tests which are required to each purpose, roughening processing and anticorrosive processing are done.
Copper foil is processed to the width and the length according to the customer's specification.
Processing to sheet products and guide bore processing for pin laminations are done. Going through inner process tests and reliability tests, etc, products which have passed the last evaluation are shipped as roll products or sheet products.
* CO2 emmsions
* Severe environmental damage from copper mining
* Production of nontoxic waste and further waste disposall
Lithium-Ion Battery Manufacturing Process involves 7 extra step after all necessary components were manufactured.
1) Drying (optional process)
2) Slitter/Puncher
3)Assembly
4)Filling
5)Formation
6)Grading
7)Packaging
*Optional: Drying of the electrode material
*Drying chamber with air humidity of approx. 0.5%
*Target: Reducing residual humidity
* Film cutting by menas of highly precise cutting/punching/laser tools
* Challenge: Avoidance of burr formation, fraying of edges or material particles on the surface
*Stacking of cells; integration in housing, contacting of electrodes; partial sealing of housing
*Challenge: Positioning accuracy of ~0.1mm
* Target: Stacking process with approx. 80 layers
per cell at maximum speed
* Evacuation, electrolyte filling, sealing and cleaning of the cell in the dry room
*Challenge: Toxic reaction with air humidity! Varying absorptivity, blistering
*Target: Rapid and homogeneous filling of the cell
*Activation by means of charging/discharging routines with gradually increasing voltage storage for 2 to 4 weeks
*Challenge: High time and coast expenditures, increased risk of fire
*Target: Assurance of operability; preparation for categorization
*Categorization by means of discharge, resistance and capacitance measuring
*Challengne: Approx. 5% deviation between grades
*Target: Identical cell characteristics in battery packs
* Sorting of cells by grades
*Challenge: Hazardous substance specifications for lithium cells; risk of fire in case of cell damage
*Relevance of transport costs for plant location decision
The Manufacturing Process for the single-use batteries include manufacturing and assembling following parts: the cathode, the separator, the anode, the seals and the lable.
The container of a typical alkaline battery, consisting of preform inserted into a steel can, also doubles as the cathode. The anode in the middle is a gel composed primarily of zinc powder. The separator between the anode and cathode is either paper or synthetic fiber that has been soaked in an electrolyte solution.
In the finished battery, a plastic seal, a steel nail, and a metal top and bottom have been added. The nail is welded to the metal bottom and extends about two-thirds of the way into the can, through the anode.
* More than 86,000 tons of these are single use alkaline batteries. Imagine, placed end to end these dead alkaline batteries alone would circle the world at least six times. About 14,000 tons of rechargeable batteries are thrown away in the United States.
*Unlike compostable trash, batteries are a hazardous waste. Sealed inside alkaline cells are harmful materials which you don’t come into contact with during normal use. When that battery enters a landfill, however, the casing can be crushed or can easily degrade. This causes mercury and other toxins to leach into the environment - the air you breath and the water you drink. Air and water - the two most necessary elements for life to exist. The other heavy metals included in batteries are nickel, cadmium, cobalt and lead - highly detrimental to your. Also in batteries are corrosive acids that can eat their way through many other materials and when these acids reach the right temperature, they can explode and release toxic fumes into the air. Many of the rechargeable batteries contain heavy metals such as nickel, cadmium, cobalt, mercury. According to the Agency for Toxic Substances and Disease Registry, cadmium can cause lung damage, kidney disease and death, while lead can damage the kidneys, nervous system and reproductive system.
*In the view of all facts, it is very hard to say which battery is better. Due to a large number of downsides, both types of batteries are hazardous and only the future will reveal an answer.
! Nevertheless, one rechargeable cell can replace up to 300 throwaway batteries, keeping the landfill free not only from the batteries themselves, but also from the paper and plastic materials that are used to package them. !