NUOVOpb · Project

Cleaner, Cheaper Lead Battery Recycling That Cuts CO2 by 89%

environmentPilotedTRL 7

Right now, recycling old car and industrial batteries means melting them down in giant furnaces — dirty, expensive, and wasteful. A UK company figured out how to dissolve the lead using chemistry instead of heat, kind of like soaking a stain out of clothes rather than burning it off. The recycled lead actually makes better batteries — lasting 50% longer with 22% more energy. And the whole process uses far less energy, produces almost no pollution, and can fit into much smaller facilities.

By the numbers

89%

CO2 emission reduction vs. traditional smelting

81%

Waste reduction vs. traditional smelting

22%

Greater energy capacity in batteries made with recycled paste

50%

Longer battery life from recycled lead oxide paste

10,000 tonnes/yr

Continuous flow production process capacity

490,000 tonnes

Target waste LABs processed per year (5-year plan, 18 facilities)

196,000 tonnes

CO2 emissions avoided annually at full scale

€9.5 billion

Expected battery recycling industry value in 2024

€71.6 billion

Global LAB market projected by 2022

€206 million

Projected annual revenue at full scale

The business problem

What needed solving

The global lead acid battery market is worth tens of billions, but recycling these batteries today requires energy-intensive smelting in large furnaces that generate heavy pollution and waste. The smelted lead then needs additional processing before it can go back into new batteries, adding cost and reducing quality. Companies in this space face rising environmental regulations, high energy costs, and growing demand for circular economy solutions — all while the market is projected to grow by 59%.

The solution

What was built

A hydrometallurgical process that recycles waste lead acid batteries without smelting, producing LAB-ready lead oxide paste directly. The project delivered a 10,000 tonnes per year continuous flow production process and completed 5 deliverables total during the 18-month project period.

Audience

Who needs this

Lead acid battery recycling companies looking to replace or upgrade smelting operationsBattery manufacturers seeking higher-quality recycled lead oxide pasteAutomotive OEMs and fleet operators with circular economy and CO2 reduction targetsTelecom and data center operators dependent on large LAB installationsWaste management companies expanding into battery recycling

Business applications

Who can put this to work

Battery recycling

any

Target: Lead acid battery recycling plants currently using smelting furnaces

If you are a battery recycler dealing with high energy costs, heavy pollution controls, and expensive furnace maintenance — this project developed a hydrometallurgical process that reduces CO2 emissions by 89% and waste by 81%. A single facility can handle 10,000 tonnes per year of waste batteries. The lower operating costs and smaller footprint mean you can run profitably at scales where smelting is not viable.

Battery manufacturing

mid-size

Target: Lead acid battery manufacturers sourcing lead oxide paste

If you are a battery manufacturer struggling with lead oxide paste quality and supply chain costs — this project produces LAB-ready paste directly from recycled batteries, skipping the extra processing step that smelted lead requires. The recycled paste creates batteries with 22% greater energy capacity and 50% longer life than current products. This means a better product at lower raw material cost.

Automotive and industrial energy storage

enterprise

Target: Fleet operators and telecom companies that rely on lead acid batteries

If you are a fleet operator or telecom tower company replacing lead acid batteries frequently — batteries made with NUOVOpb recycled paste last 50% longer and store 22% more energy. That means fewer replacements, lower total cost of ownership, and a genuinely circular supply chain for your battery needs. The technology is designed for continuous flow production at 10,000 tonnes per year scale.

Frequently asked

Quick answers

What does it cost to set up a NUOVOpb recycling facility compared to a traditional smelter?

The project received EUR 1,304,100 in EU funding for Phase 2 commercialization work. The objective states the process is 'low cost and scalable' with smaller facilities than traditional smelting. Specific capital expenditure figures per facility are not provided in the available project data.

Can this operate at industrial scale?

Yes. The project delivered a 10,000 tonnes per year continuous flow production process as a demonstrated deliverable. The 5-year commercial plan targets 18 facilities globally, processing 490,000 tonnes of waste LABs — roughly 6% of the global waste LAB market.

What is the IP and licensing situation?

AURELIUS ENVIRONMENTAL LTD is the sole partner and owner of the technology. As a single-SME project funded under SME Instrument Phase 2, all IP is held by the company. Licensing or partnership terms would need to be negotiated directly with AEL.

Does the recycled lead actually perform as well as virgin lead?

Better, according to project data. LAB-ready paste from this process creates batteries with 22% greater energy capacity and 50% longer life compared to current products on the market. This is because the process produces lead oxide paste directly, avoiding the quality degradation of the smelting route.

What about regulatory compliance for this process?

The process eliminates the major environmental liabilities of smelting — reducing CO2 emissions by 89% and waste by 81%. This positions operators well ahead of tightening emissions regulations on battery recycling. Europe already mandates 95% LAB recycling rates, so demand for cleaner recycling methods is structurally driven by regulation.

How proven is this technology?

The project ran from August 2017 to January 2019 under SME Instrument Phase 2, which funds close-to-market technologies. A 10,000 tonnes per year continuous flow production process was delivered and demonstrated. The technology has moved past laboratory testing into production-scale demonstration.

Consortium

Who built it

This is a single-company project: Aurelius Environmental Ltd, a UK-based SME that is both the sole partner and coordinator. The 100% industry consortium with no university or research institute involvement signals this is a commercially-driven venture, not an academic exercise. Funded through SME Instrument Phase 2 with EUR 1,304,100, the project was designed to bring an existing technology to market. For a potential business partner, this means one decision-maker, clear IP ownership, and a company built entirely around commercializing this specific recycling process.

How to reach the team

Aurelius Environmental Ltd (UK) — contact via company website or SciTransfer can facilitate an introduction

Order a report on this consortium

Next steps

Talk to the team behind this work.

Want to explore licensing this battery recycling technology or sourcing recycled lead paste? SciTransfer can arrange a direct introduction to the technology team.

Order a report on this topic More in Environment & Climate