BATTERY SMELTING AND LEAD REFINING
[CODE NO.3450]
Lead is a highly corrosion resistant, dense, ductile, and malleable blue-grey metal, which has been used for at least 5000 years. In some countries, however, environmental or health consequences have eliminated or reduced its use in cable sheating, petrol additives. Solder, shot, and pigments.
COST ESTIMATION
Plant Capacity : 60.00 MT/day
land & Building (5000 Sq.Mtr) : Rs. 3.3 Cr
Plant & Machinery : Rs. 1.96 Cr
Working Capital for 2 Month : Rs. 54.87 Cr
Total Capital Investment : Rs. 60.22 Cr
Rate of Return : 42%
Break Even Point : 32%
INTRODUCTION
PROPERTIES OF LEAD
CHEMICAL PROPERTIES
PHYSICAL PROPERTIES
MECHANICAL PROPERTIES
THERMAL PROPERTIES
TYPES/GRADES
BATTERY SMELTING ANG REFINING OF LEAD
SPECIFICATIONS OF RECYCLED LEAD
USES AND APPLICATIONS
THE FOLLOWING ARE THE APPLICATION AREAS OF LEAD:
TYPICAL USES
TYPICAL HISTORICAL USES FOR LEAD INCLUDED:
TYPICAL CURRENT USES FOR LEAD INCLUDE:
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
(1) SCRAP PRETREATMENT -
(2) SMELTING –
(3) REFINING –
MAINLY TWO TYPES PROCESS IS USED WHICH ARE GIVEN BELOW:
(1) VARTA PROCESS
(2) MA & CX PROCESS
DESCRIPTION OF ABOVE PROCESS ARE GIVEN BELOW:
(A) SCRAP PRETREATMENT
BATTERY BREAKING PROCESS
BATTERY BREAKING
AUTOMOTIVE BATTERY BREAKING
SINK/FLOAT PROCESS
MANUAL
TUMBLER
SINK/FLOAT PROCESS
INDUSTRIAL BATTERY BREAKING
PASTE DE-SULPHURISATION
RAW MATERIALS PROCESSING > CHARGE PREPARATION/DRYING
DRYING
HANDLING AND TRANSPORT
BUCKET ELEVATORS AND DRAG CHAINS/LINES
SCREW CONVEYORS
BUCKET ELEVATORS AND DRAG CHAINS/LINES
(B) SMELTING PROCESS (LEAD REDUCTION)
ROTARY FURNACES USED FOR THE SMELTING OF PRE-TREATED
MATERIALS
(1) PYROMETALLURGICAL METHODS
THE QUANTITY OF FLUX AND REDUCING AGENT ADDED MUST
BE CAREFULLY CONTROLLED:
(2) HYDROMETALLURGICAL METHODS
(C) LEAD REFINING PROCESS
(1) PYROMETALLURGICAL REFINING
CASTING
DROSSING
POLLUTION CONTROL PROCESS
EMISSION
CONTROLS
POLLUTION MANAGEMENT PLAN
LEAD PLANT POLLUTION CONTROL
POLLUTION CONTROL MEASURES PROVIDED
WORKING OF THE SYSTEM
FURNACE:
SETTLING CHAMBER:
GRAVITY CHAMBER/ COOLING TOWER:
CYCLONE:
BAG HOUSE:
STACK:-
PLANT AND MACHINERY
BATTERY CUTTING MACHINE
BREAKING SYSTEM & SEPARATION OF COMPONENTS
BENEFITS:
BATTERY HYDRO SEPARATION SYSTEM / BATTERY BREAKER
BHS WORKING PRINCIPLE:
BHS OPERATION:
ROTARY FURNACE
ABOUT ROTARY FURNACE
THE ADVANTAGES OF USING THE ROTARY FURNACE OVER CONVENTIONAL
METHODS (SAY BLAST/FIXED FURNACE) ARE AS FOLLOWS:
FURNACE CHARGING MACHINE:
3 STAGE AIR POLLUTION CONTROL EQUIPMENT
POLLUTION CONTROL & WASTE MANAGEMENT
DUST COLLECTOR
CYCLONE
COOLING TOWER
SPARK ARRESTER
BAG HOUSE
WET SCRUBBER
CHIMNEY
LEAD INGOT CASTING MACHINE
INTRODUCTION
OPERATING PRINCIPLE
MODEL OF INGOT CASTING MACHINE:
ADVANTAGES:
LEAD REFINING FURNACE
LEAD REFINING
OPERATING PRINCIPLE
LEAD ALLOYING
ADVANTAGES:
ECO FRIENDLY PROCESS
BLAST FURNACE
GBF BLAST FURNACES:
LEAD SMELTING
LEAD SMELTING EQUIPMENTS/LEAD SMELTING PLANT
SECONDARY LEAD SMELTING
LEAD REFINING
BATTERY SCRAP PREPARATION
SMELTING.
REFINING.
FUTURE SCENARIO OF LEAD
FUTURE DEMAND
DEMAND FORECAST BASED ON CAGR AND GDP GROWTH
DEMAND PROJECTIONS BASED ON SECTOR WISE GROWTH
(A) STORAGE BATTERIES
(B) VEHICLES
DEMAND & SUPPLY RELATIONSHIP
1. SUPPLY-DEMAND OF LEAD SCRAP IN INDIA
THE DEMAND-SUPPLY GAP MAY BE BRIDGED BY ONE OR MORE
OF THE FOLLOWING:
2. LEGISLATION ON BATTERY SCRAP
SALIENT FEATURES OF BATTERIES LEGISLATION
3. OPERATIONAL ASPECTS OF BATTERY CHANNELISATION
4. IMPACT OF BATTERIES LEGISLATION ON SUPPLY-DEMAND
5. WAY FORWARD
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF LEAD INGOT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF LEAD ACID BATTERY SCRAP
SODA ASH
COKE
IRON
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF LEAD ACID BATTERY RECYCLING PLANT
EOT CRANE
D.G. SETS
POWER TRANSFORMERS
COOLING TOWER
ETP PLANTS
AIR POLLUTION CONTROL EQUIPMENTS
AIR COMPRESSORS
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
ELECTRICAL MEASURING INSTRUMENTS
SUBMERSIBLE WATER PUMP
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
