Develop Integrated Reverse Logistics Channel for Used Lead Acid Batteries

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Presentation
Department of Industrial & Production Engineering, RUET

DEVELOP AN INTEGRATED REVERSE LOGISTICS
CHANNEL FOR USED LEAD ACID BATTERIES:
A SIMULATION APPROACH
Course Title: Project and Thesis
Course No.: IPE 4200
Supervised By
Md. Rakibul Islam
Assistant Professor, Dept. of IPE, RUET
Presented By
Maidul Islam Sakib [1605034]
Nahian Kawser Sifat [1605052]
2

Contents
• Scenario of lead acid battery
industry in Bangladesh
• Scenario of lead ingot in
Bangladesh
• Lansink’s ladder of recovery
options
• Reseach Gap
• Problem Statement
• Objectives
• Research Framework
• Important Processes
• Proposed Channel
• Simulation
• Simulated Result
• Impact Analysis
• Discussion
• Conclusions
• Referances
3

Scenario of lead acid battery industry in Bangladesh
● The total amount of ULAB generated annually in Bangladesh is estimated to be in the region of 118,000 metric ton [13].
● The annual tonnage of ULAB generated means that it is entirely possible for three or four medium sized ULAB recycling plants
(30,000+ metric ton capacity) [13] to operate in a sustainable, environmentally sound manner and be financially viable.
● Such a scenario would be a major improvement in the environmentally sound management of ULAB, because the Lead Battery
Manufacturers Association in Dhaka, believe that upwards of 80% of the Lead recycled in Bangladesh is produced in the
informal sector [13] .
● Without knowing exactly the tonnage of ULAB recycled in the formal sector, it is difficult to confirm the amount of ULAB recycled
informally, but in the absence of any official Lead production data or records of the capacities of LAB manufacturers licensed to
recycle ULAB, the default position is that the informal sector may well be the major source of Lead for the LAB
manufacturing sector.
● Besides, bad quality battery parts or ULAB at the village level cannot enter the formal reverse logistics channel. In the end those
types of batteries are dumped in the land.
● Authorities are tolerant as the informal recycling sector helps reduce the volume of waste disposed of in landfills. Informal
recycling is also acknowledged in the national Reduce, Reuse and Recycle strategy as an important source of income for the
urban poor.
4

Scenario of lead ingot in Bangladesh
The reasons behind the shortage of refined lead used for LAB manufacturing in Bangladesh is the licensed
LAB makers and ULAB recyclers are not acquiring and recycling all of the ULAB inside the licensed sector of
the industry.
It is suspected that the informal sector is selling lead ingots that has been created by them for unauthorized
export through cross-border commerce.
If licensed LAB manufacturers and ULAB recyclers in Bangladesh could collect and recycle all available
ULAB, the insufficiency in refined Lead would be close to 7,500 metric ton, saving the industry
approximately USD$ 35,000,000 because the industry would only need to procure 7,500 metric ton of Lead
instead of 21,000 metric ton [13].
5

Lansink’s ladder of recovery options
Prevention
of waste
Reuse of
products
Reuse of
components
Material
recycling
Incineration
with energy
recovery
Incineration
without
energy
recovery
Landfill
Landfill is the lowest priority order
6

Reseach Gap
By reviewing the previously published papers, it can be said that the
authors have developed reverse logistics channel only for the formal
sector, they have bypassed the informal sector. At this time, it is not
practicable in Bangladesh to maximize production through ULAB
recycling by prioritizing the formal sector and ignoring the informal
sector.
7

Problem Statement
Reverse logistics channel of formal and informal sector for ULAB recycling is different. It is
believed that 80% of lead is recycled by the informal sector in Bangladesh, but at the end
of the year there is a lack of refined lead for LAB manufacturing, because those leads
(obtained from informal) are smuggled through cross border illegal trade instead of
entering the mainstream reverse logistics channel. Besides, bad quality battery parts or
ULAB at the village level cannot enter the formal reverse logistics channel. In the end
those types of batteries are dumped in the land. Instead of such individual channels, if it
is possible to create an integrated reverse logistics channel by combining both (formal
and informal), maximum number of ULABs and lead ingots will get an opportunity to enter
the mainstream reverse logistics channel.
8

Objectives
a) To develop an integrated reverse logistics channel for used lead
acid batteries by simulation approach
b) To analyze the impact of that simulation approach
9

Research Framework
Observational Study
Identify the Research Gap
Specify the Problem
Design a Simulation Channel
Input Primary and Secondary Data
Get the Simulated Result
Impact Analysis Based on Result
10

Important Processes
Crushing and Hammering
Batteries are broken into small pieces by the effect of rotating an auto crasher or hammered using axe or
machetes. Batteries are physically smashed to recover three things mainly: lead, plastic and acid.
Pit Smelting
Informal sector's 'pit smelting' technique can reach as high as 40-45% lead losses [2]. Lead plates are
inserted into a hole drilled in the earth, and coal/charcoal is heaped around it. To keep the coal burning hot,
each furnace features a fan powered by a diesel engine. Impurities are scraped from the molten lead's
surface and chucked to the side. 1.25 tones of lead ingots are produced in 3-4 hours per night in this way.
Lead Scrap Process
Lead smelting can be carried out in a variety of furnaces, including blast furnaces and electric arc furnaces.
To capture lead-containing dust emissions, smelters are typically equipped with dust collection and air
filtration. The lead paste can then be refined with metallic lead grids after it has been reduced to metallic Pb.
Hourly capacity of rotary furnace machine is about 3 tons.
11

Pyrometallurgical Process
Lead is refined in batches ranging from 20 to 200 tons [33], depending on the capacity of the refining plant.
Thermal treatment takes place in the liquid phase, which means that the crude lead must be melted at
temperatures greater than 327ºC but less than 650ºC (lead boiling point) [33]. Pyrometallurgical machine capacity
is about 7 tons per hour.
Injection moulding
This is the most prevalent method for mass producing plastic objects. It consists of three major components: an
injection machine, a plastic injection mould, and plastic pellets. The idea is to inject molten plastic into a mould
cavity, allow it to cool, and then solidify into the same form as the cavity contour.
Acid Neutralization Process
Water from the battery crushing process is transferred to the acid neutralization section, where it is treated with
line and neutralized before reuse. The drained acid is collected in an acid gathering tray located at the machine's
base. To collect the acid fumes produced, the vacuum hoods on the top are linked to the suction blower and
scrubber. Hourly capacity of acid neutralization machine is about 2.5 ton.
12

Proposed Channel
13

Simulation
15

Simulation Platform
Arena Training and Evaluation Mode (Student),
Copyright © 2020 Rockwell Automation, Inc.
Device Specification
Device name DESKTOP-LJ9DCDK
Processor Intel(R) Core™ i5-8265U CPU @ 1.60GHz 1.80 GHz
Installed RAM 4.00 GB (3.88 GB usable)
16

Simulated Result
Amount of Lead acid battery = 5600 kg/ year or approximate 560
batteries/year.
Informal amount of lead ingot = 948 kg/ year which is add to the
mainstream LAB manufacturing.
Formal amount of lead ingot = 1561 kg/ year which is playing a role in
recycled new LAB manufacturing.
01
03
02
04
Amount of acid lost = 243 kg/ year which cannot enter the mainstream
channel.
19

Impact Analysis
20
20

21
Energy savings
The manufacturing stage of lead necessarily involves a significant quantity of
electricity, water, and some other resources. The energy usage per kilogram of
lead acid battery produced around 25 MJ [43]. If 5600 kg LAB are produced in
a single year, then 5600 × 25 = 140000 MJ is required. The total energy
needed for remanufacturing a product is 15% of the energy necessary for new
product manufacturing [44]. So, in that case, only 0.15 × 140000 = 21000 MJ is
required to remanufacture 5600 kg LAB.
21

22
Preserving Raw Material
Bangladesh has no lead mines and is entirely dependent on imports. In that
case, 948 kg of lead ingot can add value as raw material to the mainstream
LAB manufacturing system which would have been smuggled by cross border
commerce so far and the Bangladesh government would have been deprived
of a huge amount of tax.
22

23
Economic Impact
According to a source published in March, 2020, Bangladesh is spending
$ 57069885 to import 21146 metric tons of refined lead and lead scrap [13].
Accordingly, if the price of lead per kg is $2.7, the price of 948 kg of lead
(getting from informal sector) falls to $2559.6. As Bangladesh entirely
dependent on imports for chasing lead demand, there could be a huge
economic savings of $2559.6 by lead recover.
23

Discussion
The proposed channel is a smaller scaler outline of ULAB recycling and it
was not possible to consider many factors in its development due to lack
of time and data. However, the simulated results clearly show that 5600
kg of ULAB and 948 kg of lead ingot can be contributed to the
mainstream reverse logistic channel annually which gives a glimpse of
the promising ULAB recycling industry in future Bangladesh.
24

Conclusions
The use of lead acid batteries in the automotive industry in Bangladesh is increasing day by day. In
continuation of this, two different reverse logistics channels have been developed (one is licensed or formal, the
other is illegal). Both channels have some limitations and advantages. It is believed that 80% of lead is recycled
by the informal sector in Bangladesh, but at the end of the year there is a lack of refined lead for LAB
manufacturing, because those leads (obtained from informal) are smuggled through cross border illegal trade.
Besides, bad quality battery parts or ULAB at the village level cannot enter the formal reverse logistics channel.
Those types of batteries are dumped in the land. In this paper, an integrated channel is created by combining
the reverse logistics channel of both sectors through simulation. At the integrated channel, the informal sector
will play the role of smelter only and the formal sector will play both the role of smelter and new LAB
manufacturer. Thereby allowing all ULABs and lead ingots to enter the mainstream LAB manufacturing system.
By channel integration, an attempt was made to solve the specific problem identified in this paper. This
simulated result made on a smaller scale can be a replica of potential ULAB recycling in Bangladesh.
25

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