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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