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    Recycle of Lead Acid Battery (Cap: 24 Tons/Day Processing)

    Recycle of Lead Acid Battery (Cap: 24 Tons/Day Processing)
    Recycle of Lead Acid Battery (Cap: 24 Tons/Day Processing)
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      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)

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