Lead acid batteries’ carbon footprint calculation and improvement through the LCA methodology: the case of UPS and Telecom applications

Industrial lead acid batteries are the go-to solution for reserve power applications, such as uninterruptible power supplies and telecommunications, which require immediate power discharge. Their widespread usage is validated by extensive, scaled-up manufacturing and recycling infrastructures, high reliability, technological maturity, and relatively lowcost materials compared to lithium or nickel solutions. At the same time, reliance on lead and plastic materials directly links LABs to potential health and environmental concerns, particularly those arising from material extraction and refining. Nonetheless, contemporary, comprehensive evaluations of their environmental impact remain limited in the literature. In response to this gap, coherently with the framework given by Regulation EU 2023/1542, which establishes new mandatory guidelines for many different battery technologies in the European Union, this thesis applies Life Cycle Assessment to investigate the carbon footprint of LABs. The analysis starts from the bill of materials of the battery and maps the contribution of each material and process across the four principal life-cycle stages, from upstream material production through manufacturing, assembly,delivery and end-of-life. Sensitivity and scenario analyses are performed to evaluate the reliability of the results and to explore design interventions capable of lowering impacts without compromising functional performance. The findings not only provide pioneering results for LABs in terms of environmental impact but also enhance sustainable product development. Overall, the thesis tries to provide clarity on the environmental performance of LABs while proposing alternative, more sustainable design choices aimed at improving the sustainability of lead acid technology in the battery sector.