RECYCLE OF LEAD ACID BATTERY (CAP: 24 TONS/DAY PROCESSING)
[EIRI/EDPR/4723] J.C.: 2943XL
Battery recycling is a recycling activity that aims to reduce the number of batteries being disposed as municipal solid waste. Batteries contain a number of heavy metals and toxic chemicals and disposing of them by the same process as regular household waste has raised concerns over soil contamination and water pollution.
Lead-acid batteries include but are not limited to: car batteries, golf cart batteries, UPS batteries, industrial fork-lift batteries, motorcycle batteries, and commercial batteries. These can be regular lead–acid, sealed lead–acid, gel type, or absorbent glass mat batteries. These are recycled by grinding them, neutralizing the acid, and separating the polymers from the lead. The recovered materials are used in a variety of applications, including new batteries. The lead in a lead–acid battery can be recycled. Elemental lead is toxic and should therefore be kept out of the waste stream.
Lead–acid batteries collected by an auto parts retailer for recycling. The casing of a Lead–acid battery is often made of either polypropylene or ABS, which can also be recycled, although there are significant limitations on recycling plastics. Many cities offer battery recycling services for lead–acid batteries. A battery-industry promotional group, the Battery Council, says that about 99% of lead from used batteries is reclaimed.
Car battery recycling represents one of the most exciting recycling processes due to the possibility to recover important quantities of lead and plastics. The recycling process is easy and cost-effective as lead is easy to extract and can be reused multiple numbers of times. This led to many profitable businesses and the recycling of other batteries.
The battery contains around 70 % lead, 20% acid and 10% plastic case. In recycling process batteries are broken cover of batteries is removed and acid is drained out for neutralization. Top portion is hammered for shredding of plastic and the lead posts fixed in the top are released. Furnace smelting is done for approximately 5 hours at over 1000ᵒC lead and slag is tapped separately. Refining is done by lowering the temperature thereby decreasing the solubility of impurities. Once the lead is purified it is cast into ingots and reused for further purposes.
It is estimated that at least 85% of lead consumed could potentially be recycled. However, in practice the amount that is recovered is lower. Car battery recycling represents one of the most exciting recycling process due to the possibility to recover important quantities of lead and plastics. The recycling process is easy and cost-effective as lead is easy to extract and can be reused multiple numbers of times. This led to many profitable businesses and the recycling of other batteries.
COST ESTIMATION
Plant Capacity 24 MT/Day
Land & Building (5000 sq.mt.) Rs. 2.95 Cr
Plant & Machinery Rs. 3.10 Cr
Working Capital for 1 Month Rs. 6.28 Cr
Total Capital Investment Rs. 12.58 Cr
Rate of Return 40%
Break Even Point 42%
CONTENTS
INTRODUCTION
USES & APPLICATIONS
LEAD INGOTS
BATTERY
ROLLED EXTRUSIONS
PIGMENTS
CABLE SHEATHING
LEAD INGOTS FOR CAST LEAD BULLETS
LEAD ALLOYS
LEAD BATTERY – TOUCHES OUR LIVES
GOVERNMENT INITIATIVE AND OPPORTUNITIES IN BATTERY RECLING
THE PROCESS OF RECYCLING BATTERIES
COLLECTION AND SORTING OF USED BATTERIES
BREAKING DOWN AND SEPARATION OF COMPONENTS
PURIFICATION AND PREPARATION FOR REUSE
THE NEED FOR RECYCLING BATTERIES
ENVIRONMENTAL IMPACT OF IMPROPER BATTERY DISPOSAL
ECONOMIC BENEFITS OF BATTERY RECYCLING
INDIAN GOVERNMENT’S POLICY ON BATTERY RECYCLING
OVERVIEW OF THE BATTERY WASTE MANAGEMENT RULES 2022
ROLE OF EXTENDED PRODUCER RESPONSIBILITY (EPR)
THE BUSINESS OF BATTERY RECYCLING IN INDIA
CURRENT STATE OF BATTERY RECYCLING INDUSTRY IN INDIA
MAJOR COMPANIES INVOLVED IN RECYCLING BATTERIES
OPPORTUNITIES AND CHALLENGES IN THE BATTERY RECYCLING BUSINESS
MARKET OVERVIEW
GREEN RECYCLING
GLOBAL PICTURE
KEY MARKET PLAYERS
SUPPLY-DEMAND OF LEAD SCRAP IN INDIA
TRADE IN LEAD
CONSUMPTION OF LEAD
LEAD-ACID BATTERIES
COMPOSITION OF AN AVERAGE LEAD-ACID BATTERY
APPLICATIONS OF LEAD AND LEAD-ACID BATTERIES
INDIAN SCENARIO
BATTERY COLLECTION
SPECIFICATIONS
BENEFITS OF BATTERY RECYCLING
REDUCTION IN WASTE SENT TO LANDFILLS AND TURNING THEM INTO
NEW PRODUCTS
LEAD ACID BATTERY – A VIEW
THE CHEMICAL REACTION IN A LEAD-ACID BATTERY:-
BATTERY LIFE
RAW MATERIAL
DESIGN OF A STARTER BATTERY
MINIMUM REQD FACILITY AND STANDARD OFSECONDARY LEAD FACILITY
TYPE OF FURNACE INSTALLED (ROTARY/MANDIR BHATTI)
SPCBS/PCCS MAY PRESCRIBE THE FOLLOWING STANDARDS FOR
EMISSION/DISCHARGE FOR LEAD
STEPS TO MINIMIZE FUGITIVE EMISSIONS OF LEAD
LEAD RECYCLING PROCESS
LEAD RECYCLING PROCESS INCLUDES THESE FOLLOWING STEPS:
1. LEAD BATTERY BREAKING AND SEPARATION
2. DESULPHURIZATION SYSTEM
3. LEAD SMELTING
4. LEAD REFINING AND ALLOYING
5. LEAD CASTING
PROCESS FLOW SHEET OF RECYCLING SCRAP BATTERY
SEQUENCES IN LEAD ACID BATTERY RECYCLING
LEAD RECYCLING PROCESS INCLUDES THESE FOLLOWING STEPS:
LEAD BATTERY BREAKING AND SEPARATION
DESULPHURIZATION SYSTEM
LEAD SMELTING
LEAD REFINING AND ALLOYING
LEAD CASTING
GAS CLEANING SYSTEM
LEAD ACID BATTERY RECYCLING EQUIPMENTS
SMELTING
REFINING
INGOT STACKING MACHINE:-
BATTERY BREAKING AND SEPARATION
REFRACTORY
POLLUTION CONTROL EQUIPMENT & MATERIAL HANDLING
THE AIR POLLUTION CONTROL SYSTEM CONSISTS OF:
LEGISLATION ON BATTERY SCRAP
THE SALIENT FEATURES OF THE RULES ARE AS FOLLOWS:
SUPPLIERS PLANT & MACHINERY / CONSULTANT
ACS LEAD TECH
PLANT LOCATION FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
WASTE DISPOSAL:
LABOR:
SITE CHARACTERISTICS:
WASTE EFFLUENT/FLUE GAS EMISSION
SOLID WASTE MANAGEMENT
HEALTH SAFETY & ENVIRONMENT
SAFETY & OCCUPATIONAL MEASURE FOR STORAGE/HANDLING OF RAW MATERIAL & PRODUCT
ENVIRONMENTAL/SAFETY LIABILITY & ENVIRONMENT CLEARANCE PROCESS
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
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)
Why Choose Us
- More than 45 years of experience
- Managed by expert industrial consultants
- ISO 9001-2015 Certified
- Registered under MSME, UAM No: DL01E0012000
How We Work
- 24/5 Research Support Get your queries resolved from an industry expert. Ask before you purchase.
- Custom Research Service Speak to our consultants to design an exclusive study for your needs.
- Quality Assurance All reports are prepared by qualified consultants & verified by experts.
- Information Security Your personal & confidential information is always safe and secure.
Detailed Project Report (DPR) includes Present Market Position and Expected Future Demand, Technology, Manufacturing Process, Investment Opportunity, Plant Economics and Project Financials. comprehensive analysis from industry covering detailed reporting and evaluates the position of the industry by providing insights to the SWOT analysis of the industry.
Each report include Plant Capacity, requirement of Land & Building, Plant & Machinery, Flow Sheet Diagram, Raw Materials detail with suppliers list, Total Capital Investment along with detailed calculation on Rate of Return, Break-Even Analysis and Profitability Analysis. The report also provides a birds eye view of the global industry with details on projected market size and then progresses to evaluate the industry in detail.
We can prepare detailed project report on any industry as per your requirement.
We can also modify the project capacity and project cost as per your requirement. If you are planning to start a business, contact us today.
- Market growth drivers
- Factors limiting market growth
- Current market trends
- Market structure
- Key highlights
- Up-to-date analyses of market trends and technological improvements
- Pin-point analyses of market competition dynamics to offer you a competitive edge over major competitors
- An array of graphics, BEP analysis of major industry segments
- Detailed analyses of industry trends
- A well-defined technological growth with an impact-analysis
- A clear understanding of the competitive landscape and key product segments
- Ask for FREE project related details with our consultant/industry expert.
- Share your specific research requirements for customized project report.
- Request for due diligence and consumer centric studies.
- Still haven't found what you're looking for? Speak to our Custom Research Team.
EIRI Board is a single destination for all the industry, company and country reports. We feature a large repository of latest industry reports, leading and niche company profiles, and market statistics prepared by highly qualified consultants and verified by a panel of experts.
Note: We can also prepare project report on any subject based on your requirement and country. If you need, we can modify the project capacity and project cost based on your requirement.
Our reports provide an expansive market analysis of the sector by covering areas like growth drivers, trends prevailing in the industry as well as comprehensive SWOT analysis of the sector.
Our Clients
- Our research reports comprehensively cover Indian markets (can be modified as per your country), present investigation, standpoint and gauge for a time of five years*.
- The market conjectures are produced on the premise of optional research and are cross-accepted through associations with the business players.
- We use dependable wellsprings of data and databases, and data from such sources is handled by us and incorporated into the report.
- Our project reports include detailed analysis that helps get the industry's Present Market Position and Expected Future Demand.
- Offer real analysis driving variables for the business and the most recent business sector patterns in the industry.
- This report comprehends the present status of the business by clarifying a complete SWOT examination and investigation of the interest-supply circumstance.
- Report gives analysis and in-depth financial comparison of real players/competitors.
- The report gives estimates of key parameters which forecast business execution.
