The sustainable evaluation of the lead acid batteries recycling process helps to quantitatively analyse the true value of resources, the environment and the economy, and provides recommendations for improving process sustainability. However, the environmental impact of pollutants hasn't been considered in the traditional emergy indicators. To this end, an improved emergy analysis method is proposed to evaluate the efficiency and sustainability of the lead acid batteries recovery process system. Firstly, the ecological effects of pollutant emissions are converted to equivalent waste emergy using the dilution method, the eco-indicator 99 method and the land erosion method. Then, the waste emergy and product emergy are included in the emergy index system, and improved emergy indices are put forward. In addition, in order to assess the system's resource recovery rate and clean production level, technical efficiency and environmental performance indicators have been increased. Finally, according to the evaluation results of emergy indicators, provide improvement measures for the optimisation system. To verify the feasibility of the proposed method, a sustainable evaluation of the recycling process system is applied. And the results show that pollutant emissions reduce the effectiveness and sustainability of the system. This method more truly reflects the overall performance of the system, compared with the traditional emergy method. The proposed method can be utilized as an effective tool for sustainable evaluation and optimisation of lead acid batteries recovery process system.