The statutes, regulations, and instructions governing the logistical handling of batteries within the Department of Defense, especially end-of-life demilitarization and disposal are listed below. These documents guide agencies, most importantly the Defense Logistics Agency, in the ultimate processing, recycling, and transportation of battery materials:
- Technical Bulletin TB 43-0134, Battery Disposition and Disposal
- DoDI 4160.28 - DoD Demilitarization (DEMIL) Program
- DoD 4140.1-R DoD Supply Chain Materiel Management Regulation
- DoD 4160.21-M - Defense Materiel Disposition Manual
- DoD 4160.21-M-1 - Defense Demilitarization Manual
- 49 CFR - Transportation
In excess of 1,000,000 pounds of batteries are used in OCONUS theaters of operation annually. Transportation via aircraft is costly such that hazardous wastes are almost entirely disposed of using land and shipping routes. There is also a safety concern of transporting dangerous and toxic materials that could damage or destroy aircraft and result in loss of life. Previous in-theater disposition of batteries included burn pits. Batteries disposed in burn pits present potential toxicity issues to servicemen. In-theater disposition is further compounded by batteries with greater than 38V which are export controlled items. These factors suggest that an in-theater disposition capability is needed to render components inert and safe for storage and shipping.
Primary batteries are widely used for military combat applications, rescue missions, remote light beacons, and remote controls. The most common primary battery types are AA and AAA. Alkaline batteries are the most used primary battery due to their low cost and versatility. They can be stored for up to ten years, are more environmentally friendly, and are safe for transport aboard aircraft without transport and other regulations. Lithium metal primary batteries offer higher energy densities and longer shelf life, but at a higher cost and with transport regulations. Secondary batteries include lead acid, nickel cadmium, nickel metal hydride, and lithium-ion. Lead acid batteries are the oldest rechargeable battery type, although lead is toxic and cannot be disposed in landfills.
Lithium batteries, both non-rechargeable and rechargeable, offer performance advantages well above the capabilities of conventional aqueous electrolyte battery systems. They have the highest energy density (watt hours/kilogram), highest volumetric energy (watt hours/liter), and one of the best storage lives of currently available battery systems. For the soldier, while lithium batteries initially cost more, they last two to 10 times as long, which means soldiers carry fewer batteries for the same mission. This is resulting in an increasing number of lithium batteries entering the military supply chain. As more lithium batteries collect in the military theaters of operation across the globe, the disposition of these hazardous items becomes increasingly challenging.