Detailed Project Report on lead smelting and lead refining

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)