Battery Innovations and News–Late Summer 2018

This post originally appeared on the Sustainable Electronics Initiative Blog, written by Joy Scrogum.

As electronics become more ubiquitous each day, the integration of smaller electronic components into ever more products continues, and renewable energy becomes an increasingly popular strategy for addressing climate change, the ability to store and supply power efficiently and safely is all the more important. So it’s no surprise that batteries have been a hot topic in the news for the past month or so. Let’s take a moment to consider some of the highlights of recent battery-related news.

We may as well start with the well-written piece by Geoffrey A. Fowler, the Washington Post’s technology columnist, published today (9/12/18): “The problem with recycling our old tech gadgets: They explode.” This is a good article about how design choices to make electronics thinner and more portable make the recycling of electronics more difficult and dangerous.  Specifically because lithium-ion batteries are being incorporated into more products and smaller products, often without an easy–or any–way to remove those batteries. This isn’t just problematic for for extending the useful life of products. The trend makes the recycling of electronics increasingly risky while simultaneously making the economic feasibility of such efforts diminish. Recyclers need more time, special equipment, and training for proper handling, and they are at greater risk of damages caused by fires. As Fowler explains: “For all their benefits at making our devices slim, powerful and easy to recharge, lithium-ion batteries have some big costs. They contain Cobalt, often mined in inhumane circumstances in places like the Congo. And when crushed, punctured, ripped or dropped, lithium-ion batteries can produce what the industry euphemistically calls a “thermal event.” It happens because these batteries short circuit when the super-thin separator between their positive and negative parts gets breached. Remember Samsung’s exploding Note 7 smartphone? That was a lithium-ion thermal event.”

Fowler visits Cascade Asset Management, an electronics scrap processor in Madison, WI, to observe the process of removing a battery from an old iPad before the device can be sent through the shredder for recycling.  My take away from this article: products need to be designed not only with sleek aesthetics and portability in mind, but also the ability to easily and safely upgrade, repair, and maintain them during their useful life and then to easily and safely reclaim parts and component materials when they have reached their end of useful life. Fowler concludes “So as a gadget reviewer, let me say this clearly to the tech industry: Give up your thin obsession. We’ll happily take electronics with a little extra junk in the trunk if it means we can easily replace batteries to make them last longer – and feel more confident they won’t end up igniting a recycling inferno.” Do agree with his sentiment? Consider voicing that opinion to the manufacturers of your favorite devices, and if you’re an industrial design student, heed well the lessons you can learn from this article.

close up of lithium-ion laptop battery
Photo by Kristoferb, CC BY-SA 3.0

As long as we’re on the subject of “thermal events,” consider this interesting research highlighted in this article provided by the American Chemical Society : “These lithium-ion batteries can’t catch fire because they harden on impact.” ‘Lithium-ion batteries commonly used in consumer electronics are notorious for bursting into flame when damaged or improperly packaged. These incidents occasionally have grave consequences, including burns, house fires and at least one plane crash. Inspired by the weird behavior of some liquids that solidify on impact, researchers have developed a practical and inexpensive way to help prevent these fires. They will present their results today at the 256th National Meeting & Exposition of the American Chemical Society (ACS). “In a lithium-ion battery, a thin piece of plastic separates the two electrodes,” Gabriel Veith, Ph.D., says. “If the battery is damaged and the plastic layer fails, the electrodes can come into contact and cause the battery’s liquid electrolyte to catch fire.” To make these batteries safer, some researchers instead use a nonflammable, solid electrolyte. But these solid-state batteries require significant retooling of the current production process, Veith says. As an alternative, his team mixes an additive into the conventional electrolyte to create an impact-resistant electrolyte. It solidifies when hit, preventing the electrodes from touching if the battery is damaged during a fall or crash. If the electrodes don’t touch each other, the battery doesn’t catch fire. Even better, incorporating the additive would require only minor adjustments to the conventional battery manufacturing process…In the future, Veith plans to enhance the system so the part of the battery that’s damaged in a crash would remain solid, while the rest of the battery would go on working. The team is initially aiming for applications such as drone batteries, but they would eventually like to enter the automotive market. They also plan to make a bigger version of the battery, which would be capable of stopping a bullet. That could benefit soldiers, who often carry 20 pounds of body armor and 20 pounds of batteries when they’re on a mission, Veith says. “The battery would function as their armor, and that would lighten the average soldier by about 20 pounds.”

Imagine the day when lithium-ion batteries might be an asset for safety instead of a liability!

blue tray with white powder next to a white sheet of plastic
Adding powdered silica (in blue container) to the polymer layer (white sheet) that separates electrodes inside a test battery (gold bag) will prevent lithium-ion battery fires. Credit: Gabriel Veith

Writing for the HOBI International blog, Alicia Cotton recently wrote that “Innovation is making lithium-ion batteries increasingly harder to recycle.” The point of her post was that as demand for lithium-ion batteries increase, manufacturers will look to produce them with cheaper materials, adversely impacting the economic incentives for recycling these batteries. ‘According to the Royal Chemistry Society, the cost of cobalt, which is heavily used as a cathode material in all batteries, jumped from $32,500 to $81,000 in just over a year. In response, battery manufacturers have opted to redesign batteries to minimize cobalt. In May, Tesla CEO Elon Musk said the company had all but eliminated cobalt from batteries it uses in automobile and stationary batteries. However, doing so will help keep batteries cheap — as in too cheap to recycle. Without valuable contents recyclers have little incentive to capture used batteries, Kaun said.‘  This is an interesting example of trade-offs and how considerations for sustainability are rarely simple. The use of cobalt in batteries is problematic not just due to the economic cost of the material, but also due to human rights issues related to cobalt sourcing. However, this article points out that as higher value materials are phased out of design, there is a negative impact on the economics of recycling. More work is clearly needed to create recycling incentives for lithium-ion batteries moving forward, as well as developing batteries which depend less on cobalt, and improving the sustainability of the cobalt supply chain.

In another recent post for the HOBI International blog, Cotton writes that a “New Material will Triple Storage Capacity of Lithium-Ion Batteries.” Together in a joint effort, scientists from the University of Maryland (UMD), U.S. Army Research Lab and the U.S. Department of Energy’s (DOE) have been working hard to improve the storage capacity of lithium-ion batteries. Turns out, the use of extra cobalt was the answer. The scientists believe they can triple the energy density of lithium-ion battery electrodes.” Well, that would make those batteries not only have higher storage capacity, but also create an incentive for recycling them–but then we’re looking at the issues surrounding cobalt sourcing again. What did I say about trade-offs and how sustainable solutions are rarely simple? Sigh.

And, while we’re on the subject of sustainable solutions coming in shades of grey, here’s an example of how context can be important. As someone who advocates for waste reduction, I often talk about the need for more durable, repairable, upgradable goods and a move away from disposability. I certainly like to encourage people to use rechargeable batteries instead of single-use ones where they can. But there are situations in which disposable goods might actually fostersustainability, and yes, this is even true for batteries.  Another recent update from the American Chemical Society discussed “A paper battery powered by bacteria.” Consider remote areas of the world where access to electricity is a luxury, or situation in which a natural disaster or other emergency has occurred leaving an area without access to power. Think about medical devices that would be needed to help victims of a disaster, or just be part of everyday medical support in remote areas. Paper is desirable for biosensors due to its flexibility, portability, high surface area, and inexpensive nature. “Choi and his colleagues at the State University of New York, Binghamton made a paper battery by printing thin layers of metals and other materials onto a paper surface. Then, they placed freeze-dried “exoelectrogens” on the paper. Exoelectrogens are a special type of bacteria that can transfer electrons outside of their cells. The electrons, which are generated when the bacteria make energy for themselves, pass through the cell membrane. They can then make contact with external electrodes and power the battery. To activate the battery, the researchers added water or saliva. Within a couple of minutes, the liquid revived the bacteria, which produced enough electrons to power a light-emitting diode and a calculator…The paper battery, which can be used once and then thrown away, currently has a shelf-life of about four months. Choi is working on conditions to improve the survival and performance of the freeze-dried bacteria, enabling a longer shelf life.In a related article by Jason Deign for Greentech Media, Choi noted that in these low-power, low-cost situations, the paper battery could be used and then biodegrade without special treatment. Further reporting on this innovation is available in the IEEE Spectrum.

black rectangular paper batteries are held in a blue-gloved hand
Researchers harnessed bacteria to power these paper batteries. Credit: Seokheun Choi.

Now that you’ve read about all these innovations and the need for further innovations, you may be thinking, “Can someone please just tell what a lithium-ion battery is, the basics of how they work, and why we use them if there are so many problematic issues?!?!” Don’t worry–a recent post by Arthur Shi on the iFixit blog provides a nice overview with some links to more in-depth explanations if you’re interested.

Burning Need: The Search for Less-toxic Flame Retardants

DfE labelFlame retardants have been in the news again recently, as four health systems announced they would follow Kaiser Permanante’s lead by halting future purchases of furniture treated with flame retardants. As participants in the Healthier Hospitals Initiative (HHI), these health systems will specify with suppliers that upholstered furniture should not contain flame retardants where code permits. Commonly used flame retardants, particularly halogenated ones, have been found to be persistent and bioaccumulative in the environment, and have been linked to a variety of health problems, including endocrine disruption, cancer, neurotoxicity, and adverse developmental issues among others. These compounds serve as great illustration of the need for source reduction and safer alternatives considerations during P2 Week.

One such class of compounds, polybrominated diphenyl ethers or PBDEs, were commonly used in electronics, among other things. Back in 2004, a study conducted by the Electronics Take Back Coalition (then called the Computer Take-Back Campaign) and Clean Production Action found PBDEs in dust swiped from computers in university labs, legislative offices, and a children’s museum; many similar studies would further illustrate the ubiquity of these compounds in our everyday environments. That same year, penta- and octaBDEs were phased out of manufacture and import in the US. By 2009, the US producers of decaPBDE had reached an agreement with EPA to phase it out from manufacture, import and sale by 2013. DecaPBDE has been used in television casings, cell phones, and other electronics. EPA’s Design for Environment (DfE) program has conducted a Flame Retardant Alternatives for DecaBDE Partnership, which released a final report in January of this year. Three other DfE partnership programs have focused on flame retardants, underscoring the recognition by the government and industry that many of these substances require replacement with safer compounds (see the DfE partnerships related to flame retardant alternatives for HBCD, those used in circuit boards, and those used in furniture).

Despite efforts to phase out and replace specific flame retardants linked to negative impacts, these compounds continue to be a problem in general. For example, some of the phased out PBDEs may still be in your home or office, if you have older electronic devices, or furniture containing treated foam. People don’t replace items like couches all that often, and those of us attuned to sustainability try to extend the useful life of the products we own as long as possible. This situation is an example of how you really can’t define any action as being entirely “green”–it’s good to keep items longer, but the tradeoff could be continued exposure to toxins. PBDEs and other flame retardants can also present occupational exposure risks in electronics recycling facilities where the compounds can become airborne during dismantling processes. Such facilities will continue to deal with older products that contain phased out compounds into the future; you’ve probably heard about the volumes of old CRT TVs and monitors electronics recyclers deal with, and the issues surrounding the lead within them. Consider that all those old monitors probably have cases with phased-out toxic flame retardants in them as well. And if established procedures are not always successful in preventing lead exposures in recycling operations, as has recently been illustrated, then it’s also possible existing controls may not be effectively protecting workers from flame retardants. I won’t even get into the whole issue of informal recycling of electronics, and the releases of flame retardants into the environment that surely results from such operations.

To make matters worse, some of the early-adopted alternatives have already been shown to be problematic themselves. Organophosphates, for example, have been used for decades as flame retardants in consumer goods, and their use increased as a replacement for the brominated flame retardants which were being phased out. But recent studies have detected higher than expected levels of organophosphates in outdoor air, including sites around the Great Lakes, suggesting that this class of compounds, which also is associated with its own list of human health concerns, could be as persistent, toxic, and as easily transported as the compounds it replaced. One particular organophosphate, known as “tris” or “chlorinated tris” was turned to as alternative to PBDEs, and has received a lot of recent attention as a study conducted by the Environmental Working Group and Duke University scientists was released showing blood levels of tris in toddlers that were on average five times higher than that in their mothers. Since toddlers are more sensitive than adults to chemicals that can effect hormones and metabolism, this finding is particularly disturbing. It’s likely that this result is due to the fact that these compounds so readily leach out of products, like furniture, and get into dust, just as PBDEs were shown to. Since toddlers tend to play on the floor and pop objects into their mouths, they’re at increased risk of exposure to toxin-laden dust than adults. It’s interesting to note that tris was eliminated from use in children’s pajamas in 1977 when it was found to be mutagenic, but it has continued to be used in other products, particularly in the types of foams found within furniture.

The multitude of issues related to these compounds have lead others, besides the health care systems mentioned earlier, to advocate for limiting exposure to flame retardants period, and re-examining their widespread use. The Green Science Policy Institute, for example, argues that flame retardants are used, particularly in electronics, in instances beyond those in which evidence supports the need for external resistance to candle flame ignition. (See The Case against Candle Resistant TVs published earlier this year, and The Case against Candle Resistant Electronics from 2008). Among other issues, they point out that widespread flame retardant chemical use may pose a clear occupational exposure threat to firefighters, since once a fire does start, the by-products released from the burning of materials containing them may cause greater risk to firefighter health than smoke not containing such by-products. They are not the only entity to suggest this (see this article in the Huffington Post, for example).

Incidentally, polychlorinated biphenyls (PCBs) were once used as flame retardants, among other things; their production was banned in the US in 1979 due to their toxicity and persistence in the environment. Despite this, we are still dealing with exposure to PCBs and how to properly dispose of materials containing PCBs. Just yesterday (9/17), a workshop addressing PCBs and Their Impact on Illinois was held at the University of Illinois at Chicago and simultaneously broadcast at the Illinois Sustainable Technology Center (ISTC), host agency for both GLRPPR and the Sustainable Electronics Initiative. Part of the impetus for the workshop was a recent political controversy over whether to allow a landfill situated over a large aquifer to be permitted to accept materials containing PCBs. Options for safe disposal of PCB contaminated materials remain limited and expensive. Like PBDEs, PCBs fell into the category of halogenated flame retardants; in their case the halogen involved was chlorine rather than bromine.

And like PCBs, other types of flame retardants are likely to persist not only in the environment, but on our list of headaches to deal with in terms of policy and disposal/clean up, well beyond the time at which any specific one of them may be banned or phased out. They represent a current, easy-to-relate-to example of why pollution prevention techniques, such as the employment of green chemistry, green engineering, and design for environment during the product design and development phase are so essential to human and environmental well being.

Join Us for a Webinar on Sustainable Electronics Wednesday, Sept. 19

Join us tomorrow, September 19 at noon Central time, when Dr. Callie Babbitt of the Rochester Institute of Technology presents “Adapting Ecological Models for Linking Sustainable Production and Consumption Dynamic in Consumer Electronic Product Systems.” Registration for the webinar is available at https://www4.gotomeeting.com/register/541176247. Continue reading “Join Us for a Webinar on Sustainable Electronics Wednesday, Sept. 19”

Webinar–“Electronic Waste: Our Problem and What We Should Do About It”

Join us for a webinar on Wednesday, September 5, 2012, 12:00 PM to 1:00 PM CDT. This seminar will be hosted live at the Illinois Sustainable Technology Center (ISTC) in Champaign, IL, and simultaneously broadcast online. The presentation will be archived on the ISTC web site (see http://www.istc.illinois.edu/about/sustainability_seminars.cfm for more information and additional webinar archives).

Presenters include William Bullock, Affiliate with the Illinois Sustainable Technology Center and Professor of Industrial Design in the School of Art and Design, U of I at Urbana-Champaign; and Joy Scrogum, Emerging Technologies Resource Specialist at the Illinois Sustainable Technology Center, Prairie Research Institute, U of I at Urbana- Champaign.

See the Sustainable Electronics Initiative (SEI) Blog for further information and a link to the online registration form.

2012 International E-Waste Design Competition Announced

e-waste competition logoThe Sustainable Electronics Initiative has announced the 2012 International E-Waste Design Competition. Registration is free and open to current and recent college and university students, from any discipline, throughout the world. Participants submit ideas on products or services that will either prevent the generation of e-waste by prolonging the useful life of electronic products, or that reuse e-waste components in a new product. Entries include, among other components, a brief YouTube video describing the proposed product or service. Registration opens September 1, 2012. For full details, see the announcement on the Sustainable Electronics Initiative Blog.

As part of its continuing partnership with the Sustainable Electronics Initiative, GLRPPR will be co-hosting a series of webinars focused on sustainable electronics research and issues in Fall 2012. Look for more information on the presenters here in the GLRPPR Blog in late August, and check the GLRPPR Calendar for the webinars, as scheduling is confirmed.

Deadline Extended for International E-Waste Design Competition

International E-Waste Design Competition LogoThere’s still time to submit entries for the 2011 International E-Waste Design Competition. The deadline has been extended to 4:59 p.m. CT, May 9, 2011. College students and recent graduates from around the world submit ideas for reusing e-waste to create new and useful products, or for preventing its generation in the first place (e.g. by re-designing an existing electronic device to facilitate reuse or otherwise extend the product life cycle). Entries include, among other elements, a video uploaded to YouTube highlighting the proposed design idea. Six winning teams or individuals (three in each of two categories) will receive monetary prizes. The competition is part of the educational component of the Illinois Sustainable Technology Center (ISTC) Sustainable Electronics Initiative (SEI; www.sustainelectronics.illinois.edu). For more information and online registration, see www.ewaste.illinois.edu, or contact Joy Scrogum at jscrogum@istc.illinois.edu or 217-333-8948.

ISTC Technical Assistance Program Director Moving On After 19 Years

Dr. Tim Lindsey is leaving the Illinois Sustainable Technology Center (ISTC) to take another job with the University of Illinois.  Dr. Lindsey has been an Associate Director of ISTC and head of the Technical Assistance Program.

He now will be the Director of Energy and Sustainable Business Programs at the U of I – Business Innovation Services (BIS).  He will lead the State’s Green Jobs Initiative and will also direct the State’s efforts to create a stronger local foods industry. Business Innovation Services (BIS) provides customized consulting and training services, as well as public workshops and certificate programs.

“It has been a pleasure to work with Tim,” said Dr. Manohar Kulkarni, PE; Director of ISTC.  “Tim is an innovator; passionate about pollution prevention; and a gentleman.  While his daily presence at the center will certainly be missed, I hope to work with Tim on collaborative projects in his new role.  On behalf of the scientists and staff of ISTC, I wish Dr. Lindsey a roaring success in his future endeavors.”

Lindsey recently received a P2 Champion award from the National Pollution Prevention Roundtable.  He has been at ISTC since 1991 and has directed the program that included work in pollution prevention, green business, energy efficiency, alternative energy, carbon foot-printing, water foot-printing, environmental cost analysis, life cycle analysis, and systems engineering.  He is best known for his pioneering work in developing Accelerated Diffusion of Pollution Prevention Technologies (ADOP2T), a model for technology diffusion that speeds the transfer of better environmental technologies and processes from the bench to the plant floor. Lindsey is the driving force behind the Sustainable Electronics Initiative, and has been the leader in ISTC’s effort to promote and improve biofuels.  In recent years, Lindsey has applied his expertise and passion to address sustainability problems in Haiti.  He has worked with local farmers and non-government organizations to set up biodiesel processors and to train Haitians in harvesting a suitable crop like Jatropha, processing it, and operating reactors to produce a quality bio-fuel.

Lindsey was previously employed at Exxon and worked as an environmental consultant.  He received his B.S. and M.S. in Environmental Science from Southern Illinois University and his Ph.D. in Urban and Regional Planning from the University of Illinois.

We offer Tim our congratulations and best wishes. Those of us at ISTC will greatly miss him!

ISTC Receives Pair of National Environmental Awards

The Illinois Sustainable Technology Center (ISTC) has received a pair of national environmental awards. Awards were received for the Sustainable Electronics Initiative (SEI) and by Dr. Tim Lindsey.

MVP2 Awards

The 2010 Most Valuable Pollution Prevention (MVP2) awards presented by the National Pollution Prevention Roundtable (NPPR) celebrate the successes of innovators in the areas of pollution prevention and sustainability. These prestigious awards were presented recently at a ceremony in Washington, DC.  ISTC is a unit of the Institute of Natural Resource Sustainability at the University of Illinois at Urbana-Champaign. Continue reading “ISTC Receives Pair of National Environmental Awards”

International E-waste Design Competition Turns Refuse into Resource

Electronic waste, or “E-Waste,” generated by computers, TVs, cameras, printers, and cell phones, is a growing global issue. According to the U.S. EPA, Americans currently own nearly 3 billion electronic products and as new products are purchased, obsolete products are stored or discarded at alarming rates. About two-thirds of the electronic devices removed from service are still in working order. However, only about 15% of this material is recycled while the vast majority is disposed in landfills. The Sustainable Electronics Initiative (SEI), hosted by the Illinois Sustainable Technology Center (ISTC), is pleased to announce the International E-Waste Design Competition, in which participants will explore solutions to this problem at the local level and beyond, by using e-waste components to create appealing and useful products. Continue reading “International E-waste Design Competition Turns Refuse into Resource”