Detailed Project Report on battery smelting and lead refining

BATTERY SMELTING AND LEAD REFINING
[CODE NO.3450]  

Lead is a highly corrosion resistant, dense, ductile, and malleable blue-grey metal, which has been used for at least 5000 years. In some countries, however, environmental or health consequences have eliminated or reduced its use in cable sheating, petrol additives. Solder, shot, and pigments.


COST ESTIMATION

Plant  Capacity                                              :     60.00 MT/day             
land & Building (5000 Sq.Mtr)                    :    Rs.    3.3   Cr
Plant & Machinery                                        :    Rs.    1.96  Cr
Working Capital for 2 Month                      :    Rs.    54.87 Cr
Total Capital Investment                            :    Rs.    60.22 Cr
Rate of Return                                              :    42%
Break Even Point                                         :    32%


INTRODUCTION    
PROPERTIES OF LEAD    
CHEMICAL PROPERTIES    
PHYSICAL PROPERTIES    
MECHANICAL PROPERTIES    
THERMAL PROPERTIES    
TYPES/GRADES    
BATTERY SMELTING ANG REFINING OF LEAD    
SPECIFICATIONS OF RECYCLED LEAD    
USES AND APPLICATIONS    
THE FOLLOWING ARE THE APPLICATION AREAS OF LEAD:    
TYPICAL USES    
TYPICAL HISTORICAL USES FOR LEAD INCLUDED:    
TYPICAL CURRENT USES FOR LEAD INCLUDE:    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
(1) SCRAP PRETREATMENT -    
(2) SMELTING –    
(3) REFINING –    
MAINLY TWO TYPES PROCESS IS USED WHICH ARE GIVEN BELOW:
(1) VARTA PROCESS    
(2) MA & CX PROCESS    
DESCRIPTION OF ABOVE PROCESS ARE GIVEN BELOW:    
(A) SCRAP PRETREATMENT    
BATTERY BREAKING PROCESS    
BATTERY BREAKING    
AUTOMOTIVE BATTERY BREAKING    
SINK/FLOAT PROCESS    
MANUAL    
TUMBLER    
SINK/FLOAT PROCESS    
INDUSTRIAL BATTERY BREAKING    
PASTE DE-SULPHURISATION    
RAW MATERIALS PROCESSING > CHARGE PREPARATION/DRYING    
DRYING    
HANDLING AND TRANSPORT    
BUCKET ELEVATORS AND DRAG CHAINS/LINES
SCREW CONVEYORS    
BUCKET ELEVATORS AND DRAG CHAINS/LINES    
(B) SMELTING PROCESS (LEAD REDUCTION)    
ROTARY FURNACES USED FOR THE SMELTING OF PRE-TREATED
    MATERIALS    
(1) PYROMETALLURGICAL METHODS    
THE QUANTITY OF FLUX AND REDUCING AGENT ADDED MUST
   BE CAREFULLY CONTROLLED:    
(2) HYDROMETALLURGICAL METHODS    
(C) LEAD REFINING PROCESS    
(1) 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:    
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    
BHS WORKING PRINCIPLE:    
BHS OPERATION:    
ROTARY FURNACE    
ABOUT ROTARY FURNACE    
THE ADVANTAGES OF USING THE ROTARY FURNACE OVER CONVENTIONAL
   METHODS (SAY BLAST/FIXED FURNACE) ARE AS FOLLOWS:    
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    
LEAD REFINING    
OPERATING PRINCIPLE    
LEAD ALLOYING    
ADVANTAGES:    
ECO FRIENDLY PROCESS    
BLAST FURNACE    
GBF BLAST FURNACES:    
LEAD SMELTING    
LEAD SMELTING EQUIPMENTS/LEAD SMELTING PLANT    
SECONDARY LEAD SMELTING    
LEAD REFINING    
BATTERY SCRAP PREPARATION    
SMELTING.    
REFINING.    
FUTURE SCENARIO OF LEAD    
FUTURE DEMAND    
DEMAND FORECAST BASED ON CAGR AND GDP GROWTH    
DEMAND PROJECTIONS BASED ON SECTOR WISE GROWTH    
(A) STORAGE BATTERIES    
(B) VEHICLES    
DEMAND & SUPPLY RELATIONSHIP    
1. SUPPLY-DEMAND OF LEAD SCRAP IN INDIA    
THE DEMAND-SUPPLY GAP MAY BE BRIDGED BY ONE OR MORE
   OF THE FOLLOWING:    
2. LEGISLATION ON BATTERY SCRAP    
SALIENT FEATURES OF BATTERIES LEGISLATION    
3. OPERATIONAL ASPECTS OF BATTERY CHANNELISATION    
4. IMPACT OF BATTERIES LEGISLATION ON SUPPLY-DEMAND    
5. WAY FORWARD    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF LEAD INGOT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF LEAD ACID BATTERY SCRAP    
SODA ASH    
COKE    
IRON    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF LEAD ACID BATTERY RECYCLING PLANT    
EOT CRANE    
D.G. SETS    
POWER TRANSFORMERS    
COOLING TOWER    
ETP PLANTS    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
ELECTRICAL MEASURING INSTRUMENTS    
SUBMERSIBLE WATER PUMP    

                            
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