Detailed Project Report on battery recycling and manufacturing plant

BATTERY RECYCLING
AND MANUFACTURING PLANT
 [CODE NO.3487]  


The lead acid-battery is the most commonly used in solar power system applications.

Lead Acid Storage Batteries is an electro-chemical system that converts electrical energy into direct current electricity. It is also known as storage batteries and has wide applications in Automobiles, UPS/Inverters, Traction/Electrical Sub-Station, Telecommunication, Solar Photovoltaic system etc.


COST ESTIMATION

Plant  Capacity                                                 :    1,00,000.00 Nos/annum                   
land & Building  (10000 Sq.Mtr)                   :     Rs. 5.84  Cr
Plant & Machinery                                           :    Rs. 3.45  Cr
Working Capital for 2 Months                       :    Rs. 12.81 Cr
Total Capital Investment                                :    Rs. 22.63 Cr
Rate of Return                                                 :       64%
Break Even Point                                            :    34%


INTRODUCTION    
TYPES OF LEAD ACID BATTERY    
MAINLY TWO TYPES    
1. FLOODED LEAD-ACID BATTERIES    
MERITS OF VENTED BATTERY    
DEMERITS OF VENTED BATTERY    
2. SEALED LEAD-ACID BATTERIES    
MERITS SEALED LEAD ACID BATTERY    
USER FRIENDLY.    
DEMERITS OF LEAD BATTERY    
WORKING PRINCIPLE OF LEAD ACID BATTERY    
MATERIALS USED FOR LEAD ACID STORAGE BATTERY CELLS    
CONSTRUCTION OF LEAD ACID BATTERY    
LEAD ACID BATTERY CONTAINER    
LEAD ACID BATTERY PLATES    
PLANTE PROCESS    
STRUCTURE OF PLANTE PLATE    
FAURE PLATE    
PARTS OF LEAD ACID BATTERY    
B.I.S SPECIFICATION    
MARKET POSITION    
SCRAP LEAD-ACID BATTERY RECYCLING PROJECT SETTLES IN INNER MONGOLIA    
SMM: HOW WILL LEAD INDUSTRY DEVELOP IN 2017?    
GLOBAL LEAD ACID BATTERY MARKET TO REACH AROUND US$ 80 BN BY 2026    
MONGOLIAN ENERGY SECTOR    
AND ENERGY RESOURCES    
MANUFACTURERS/SUPPLIERS/EXPORTERS    
OF LEAD ACID BATTERY    
MANUFACTURING PROCESS    
1. FIRST PROCESS    
(1) COLLECTION OF USED BATTERY    
(2) TRANSPORTATION    
(3) STORAGE    
(4) BATTERY BREAKING    
1. MANUAL BATTERY BREAKING    
2. AUTOMATIC BATTERY BREAKING    
POTENTIAL SOURCES OF ENVIRONMENTAL CONTAMINATION    
(5) LEAD REDUCTION    
(A) PYROMETALLURGICAL METHODS    
DESULPHURIZATION    
THE QUANTITY OF FLUX AND REDUCING AGENT ADDED MUST BE CAREFULLY CONTROLLED:    
(B) HYDROMETALLURGICAL METHODS    
POTENTIAL SOURCES OF ENVIRONMENTAL CONTAMINATION    
(6) LEAD REFINING    
PYROMETALLURGICAL REFINING METHOD    
POTENTIAL SOURCES OF ENVIRONMENTAL CONTAMINATION    
SOME SOURCES OF ENVIRONMENTAL IMPACTS IN THE LEAD REFINING PROCESS ARE:    
(2) SECOND PROCESS    
PRODUCTION OF LEAD ACID BATTERY    
(A) PRODUCTION OF CONTAINER AND COVER    
PROCESS    
(B) MANUFATURING PROCESS OF PLATES    
1. CASTING OF GRID    
PROCESS    
2. TRIMMING OF GRID    
(C) PRODUCTION OF LEAD OXIDE    
PROCESS:    
(D) PREPARATION OF PASTE    
PASTE FOR POSSITIVE PLATE    
PASTE FOR NEGATIVE PLATE    
(E) PASTING TO GRID    
PROCESS    77
(E) CURRING AND DRYING    
(F) FORMATION    
PROCESS    
(G) ASSEMBLY    
2. GROUP BURNING:    
3. GROUP STRAPPING:    
4. GROUP INSERTION:    
5. HEAT SEALING:    
6. POST BURNING:    
7. LEAK TESTING    
(H) TESTING OF BATTERY    
(1) STATIC BATTERY VOLTAGE TEST    
(2) STARTING LOAD TEST    
(3) CHARGING SYSTEM TEST    
(4) AIR LEAKAGE TESTING:    
AIR TESTER    
(I) QUALITY CONTROL    
(2) QC FOR PLATE PREPARATION    
A) GRID TEST    
B) LEAD OXIDE TEST    
C) PASTED PLATE TEST AFTER PASTING    
C) PASTED PLATE TEST AFTER CURING    
(1) QC FOR SMELTING    
(3) Q.C FOR FORMATION    
A) CADMIUM TEST    
B) CHARGED PLATE TEST AFTER WASHING AND DRYING    
(4) Q.C FOR ASSEMBLY    
A) DESTRUCTIVE TEST    
B) SHORT AND POLARITY TEST    
C) SHEAR TEST AND LEAK TEST    
(5) Q.C FOR FINISHED BATTERY TESTING    
A) CAPACITY TEST    
B) RC TEST    
C) LIFE CYCLE TEST    
D) SELF DISCHARGE TEST    
(J) FINISHING & DESPATCHING:    
PROCESS FLOW CHART    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
LEAD ACID BATTERY SCRAP    
SODA ASH    
COKE    
ANTIMONEY POWDER    
FIBRE FLOCK    
CARBON BLACK    
BARIUM SULPHATE    
BATTERY SEPARATOR    
SULFURIC ACID    
SUPPLIERS OF COMPLETE PLANT FOR RECYCLING LEAD ACID BATTERY    
SUPPLIERS OF LEAD ACID BATTERY MANUFACTURING PLANT    
INDIAN SUPPLIERS OF LEAD ACID BATTERY RECYCLING PLANT    
EOT CRANES    
POWER TRANSFORMERS    
COOLING TOWER    
EFFULENT TREATMENT PLANT    
MATERIAL HANDLING EQUIPMENTS    
AIR COMPRESSOR    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
PLATFORM WEIGHING MACHINE    
ELECTRICAL PANEL    
                                  
        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET