Industrial and utility organisations are increasingly deploying sustainable technologies across their operations. Batteries bring environmental advantages throughout their lifecycle – from manufacture and operation to recycling and reuse, says Michael Sagar at EnerSys.
Industrial and utility organisations depend on batteries for reliable power across their operations. Well-proven chemistries such as pure lead, including thin plate pure lead (TPPL), offer a compelling combination of performance attributes such as high energy densities and fast charging rates. These characteristics make them suitable for various applications, such as uninterruptible power supply for mission-critical systems, and for telecommunications, lighting, and other essential services.
The uptake of battery power is reflected in buoyant market statistics. Recent research from Markets and Markets reveals that the global market for batteries in applications such as utilities and industrial sectors was valued at $21.2 billion in 2024 and is expected to reach $34.7 billion by 2029 – an annual compound growth rate of 10.3%. Batteries play an essential role in modern and flexible industrial and utility operations, and continued enhancements will likely see them expand into other use cases in more electrified environments.
However, while performance remains the top selection criterion for batteries, there is another crucial reason why they are proving so popular: sustainability. The ongoing battle against climate change means that many companies are committed to deploying well-designed products and systems that effectively use raw materials, have low maintenance requirements, and can be recycled at the end of life. By embracing sustainable technologies, companies realise they can achieve long-term resilience while contributing positively to environmental stewardship.
Sustainable production processes
So, what precisely makes batteries a sustainable option? A key component is the manufacturing process. Modern battery manufacturing plants now make more extensive use of automated technologies, making them far more streamlined and efficient than perhaps they used to be.
In the past, the manufacture of pure lead batteries, including TPPL, involved many manual processes such as lead paste preparation, battery grid fabrication, plate pasting and curing, and assembly of cells. In post-production, meanwhile, employees were very much ‘hands-on’ being involved with quality control, inspection, finishing, labelling, and packaging. These days, many of these manual processes have been automated to achieve better optimisation of materials, higher production speeds, improved product consistency, and enhanced quality – each of these advances supports more sustainable operations.
In recent times, there have been several examples of investment in automated and digitised high-speed lines at battery plants globally to increase output and reduce energy consumption. Reducing the amount of human interaction in the manufacturing process – with less manual handling activity on the production line – can reduce the need for rework. This transition results in more streamlined operations and lower associated waste and energy costs.
More generally, many battery companies are examining how advanced technologies such as automated guided vehicles, robotics, conveyors, and vision systems – often underpinned by rapidly evolving disciplines such as artificial intelligence and machine learning – can be adopted in production environments. This transition will further reduce the environmental impact of battery manufacturing activities.
Innovative heating solutions
Other production initiatives can also reap sustainability rewards. The manufacturing process for lead batteries requires melting lead in pots for casting and grid production. Traditionally, this process involves heating several tons of the metal with a large, gas-fired burner. Not only does this process produce greenhouse gas emissions from combustion, but it also has less than optimal effects on the equipment. Gas heating is inefficient, as the direct application of heat to melt lead can cause stress in steel pots and ultimately result in cracks over time. A cracked pot can lead to a potentially dangerous situation for both workers and the environment.
With safety and environmental stewardship in mind, EnerSys has decided to transform its manufacturing into a safer process. The energy required for heating will now come from electricity, which is increasingly produced from renewable sources. Electrification of the melting process lowers the carbon footprint of the batteries. Alongside electrification efforts, EnerSys is continuously seeking to refine and improve other aspects of the melting process to further reduce the carbon footprint of its batteries. Furthermore, as our electrical transmission and distribution grids decarbonise – and batteries play a role in that too – the process approaches carbon neutral, which would not be possible with gas-fired processes.
Field deployment and maintenance
The sustainability advantages of batteries are not restricted to the production process. Once batteries are deployed in the field, environmental advantage can be delivered by reduced maintenance stemming from inherent design and manufacturing characteristics.
Pure lead batteries use high-quality materials, thin plates, and advanced sealing techniques, giving them a lifespan of up to 15-20 years. Reduced gassing and high recombination efficiency within batteries minimise water loss, eliminating the need to top up the electrolyte with distilled or deionised water saving both water and the energy needed to purify it. Additionally, pure lead batteries with pure lead grids are more corrosion-resistant than other battery chemistries. Furthermore, the overall enclosure (container and lid) in which each battery is housed exhibits industry-leading robustness. The ability of these enclosures to deal with heavy shocks and vibrations supports longevity in the field.
These factors, in combination, reduce the need for regular maintenance activities and associated ‘truck roll’ visits to the site. Reduced maintenance requirements translate to fewer resources consumed and less environmental impact over the lifespan. Meanwhile, pure lead batteries are also very efficient on float charge due to lower internal resistance. Operating at a lower float current than conventional lead-acid batteries reduces electricity consumption, therefore lowering Scope 2 Greenhouse gas emissions (from electricity) for the end user. Ultimately, pure lead batteries offer reliable and low-maintenance performance in industrial and utility environments – reducing lifecycle costs and enhancing sustainability credentials.
Recycling and reuse
Although pure lead batteries are built to last, inevitably they reach their end of life at some point. However, there is also a sustainability story to be told here, with recycling and reuse coming into play as part of the circular economy. Research from the Battery Council International (BCI) shows that lead batteries’ three main components (lead, plastic, acid) are 100% recyclable. Lead ingots are used to manufacture new battery grids, while plastic is recovered to make new covers and cases.
Meanwhile, electrolytes can also be reclaimed and reused to manufacture new batteries. In other cases, compounds such as sodium sulfate can be separated from used electrolytes and recycled or sold for use in textile glass and detergent manufacturing. Indeed, according to the BCI National Recycling Rate Study, lead batteries are the most recycled consumer product in the United States, with an outstanding recycling rate of 99%.
This well-established closed-loop life cycle, means lead batteries are a hugely advantageous component of the transition to a low-carbon, circular economy. Looking forward with the maturity of other battery chemistries in mind, EnerSys is also working in collaboration with trade associations and other stakeholders to instigate a similar recycling process for lithium-ion batteries, which contain metals like lithium, cobalt, nickel, and copper. This chemistry brings different challenges at the end of the lifecycle, and EnerSys is helping develop new processes and technologies for recovering lithium-ion battery parts that are less impactful on the environment, whether that is through a lower carbon footprint or producing less per- and poly-fluoroalkyl substances (PFAs). This ongoing work will continue to feed into the sustainability narrative around new energy-storage products.
Conclusion
The adoption of battery technology can therefore be shown to deliver significant sustainability benefits across the lifecycle – from manufacture and operation to recycling and reuse. Chemistries such as TPPL have been proven through many years of field deployment and they are also proved to be environmentally sound. These factors mean batteries will continue to provide reliable, resilient and sustainable power for industrial and utility organisations – now and in the future.
For more information on high-performance utility and industrial batteries by EnerSys, visit enersys.com.
