LEAD SMELTING AND LEAD REFINING
[CODE NO,4236]
Lead is a chemical element with Pb as its symbol. It belongs to group 14 of the periodic table and its atomic number is 82.
Lead has been in use for centuries. It is usually found in the ores of silver, zinc, and copper. This metal is soft, dense, and ductile, and is known to be malleable and corrosion resistant. When lead is cut, it is bluish-white in color; however on exposure to air it tarnishes to a dull grayish color.
Lead is a toxic element and has to be used and disposed with caution with minimal exposure to humans.
Chemical Properties
The chemical properties of lead are provided in the table below.
Chemical Data
CAS number 7439-92-1
Thermal neutron cross section 0.17 barns/atom
Electrode potential -0.126 V
Ionic radius 0.840 Å
Electro negativity 1.8
X-ray absorption edge 0.14077 Å
Electrochemical equivalent 3.858 g/A/h
Physical Properties
The following table discusses the physical properties of lead.
Properties Metric Imperial
Density (@20°C/68°F) 11.34 g/cm3 0.409 lb/in3
Melting point 327°C 621°F
Boiling point 1755°C 3191°F
Mechanical Properties
The mechanical properties of lead are tabulated below.
Properties Metric Imperial
Tensile strength 18 MPa 2610 psi
Poisson’s ratio 0.42 0.42
Modulus of elasticity 14 GPa 2030 ksi
Shear modulus 4.90 GPa 711 ksi
Hardness, Brinell 4.2 4.2
Hardness, Vickers 5 5
Thermal Properties
The thermal properties of lead are tabulated below.
Properties Metric Imperial
Thermal expansion co-efficient (@20-100°C/68-212°F) 29.1 µm/m°C 16.2 µin/in°F
Thermal conductivity 33 W/mK 229 BTU in/hr.ft².°F
COST ESTIMATION
Plant Capacity 50 MT/Day
Land & Building (20,000 sq.mt.) Rs. 13.34 Cr
Plant & Machinery Rs. 3.82 Cr
Working Capital for 2 Months Rs. 46.35 Cr
Total Capital Investment Rs. 63.88 Cr
Rate of Return 49%
Break Even Point 31%
- INTRODUCTION
- CHEMICAL PROPERTIES
- PHYSICAL PROPERTIES
- MECHANICAL PROPERTIES
- THERMAL PROPERTIES
- TYPES / GRADES
- SPECIFICATIONS OF RECYCLED LEAD
- USES AND APPLICATION
- TYPICAL USES
- TYPICAL HISTORICAL USES FOR LEAD INCLUDED:
- TYPICAL CURRENT USES FOR LEAD INCLUDE:
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- MAINLY TWO TYPES PROCESS IS USED WHICH ARE GIVEN BELOW:
- (1) VARTA PROCESS
- (2) MA AND CX PROCESS
- BATTERY SCRAPS PREPARATION.
- BATTERY BREAKING PROCESS
- BATTERY BREAKING
- FIG: HAMMER MILL
- AUTOMOTIVE BATTERY BREAKING
- MANUAL
- TUMBLER
- FIG. 3: ENCLOSED AND EXHAUST VENTILATED TUMBLER AND DUCT WORK
- SINK/FLOAT PROCESS
- FIG. 4: VIEW OF SINK/FLOAT SYSTEM
- FIG. 5: SCREW CONVEYORS REMOVING LEAD BEARING MATERIAL FROM A TANK IN THE SINK/FLOAT PROCESS
- INDUSTRIAL BATTERY BREAKING
- PASTE DE-SULPHURISATION
- DRYING
- HANDLING AND TRANSPORT
- BELT CONVEYORS
- POTENTIAL SOURCE OF EXPOSURE:
- SCREW CONVEYORS
- BUCKET ELEVATORS AND DRAG CHAINS/LINES
- SMELTING PROCESS (LEAD REDUCTION)
- FIG: ROTARY DRUM FURNACE
- SHAFT FURNACE
- REFINING PROCESS
- 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:
- THE FOLLOWING REACTIONS CAN TAKE PLACE;-
- 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
- ADVANTAGES:
- BHS WORKING PRINCIPLE:
- BHS OPERATION:
- ROTARY FURNACE
- ABOUT ROTARY FURNACE
- 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
- OPERATING PRINCIPLE
- LEAD ALLOYING
- ADVANTAGES:
- BLAST FURNACE
- GBF BLAST FURNACES:
- MARKET POSITION
- IMPACT OF COVID-19 ON RECYCLED LEAD MARKET
- SOME OF THE KEY PLAYERS IN THE RECYCLED LEAD MARKET ARE-
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF LEAD INGOT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF LEAD ACID BATTERY SCRAP
- SUPPLIERS OF SODA ASH
- SUPPLIERS OF COKE
- SUPPLIERS OF IRON
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF LEAD RECYCLING PLANT
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMER
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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