Detailed Project Report on lead smelting plant

LEAD SMELTING PLANT
[CODE NO.3397]


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.

Lead has the highest rate of recycling of all the metals. Due to its corrosion resistance, lead scrap is available for recycling, decades or even centuries after it is manufactured. New environmental regulations in several countries has greatly reduced the dissipative uses for lead, including paint, pigments, leaded gasoline, stabilizers, solder, and ammunition.

Currently, just about half of the total world lead production of 4.7 million tons comes from the recycling of lead scrap. In recent years, the amount of recycled lead has been increasing and this rate of lead production is expected to increase in the future.

Most of the lead produced comes from secondary sources. Lead scrap includes lead acetate batteries, cable coverings, pipes, sheets and lead coated, or terne bearing, metals. Solder, product waste and dross may also be recovered for its small lead content. Most secondary lead is used in batteries.

To recover lead from a battery, the battery is broken and the components are classified. The lead containing components are processed in blast furnaces for hard lead or rotary reverberatory furnaces for fine particles. The blast furnace is similar in structure to a cupola furnace used in iron foundries. The furnace is charged with slag, scrap iron, limestone, coke, oxides, dross, and reverberatory slag. The coke is used to melt and reduce the lead. Limestone reacts with impurities and floats to the top. This process also keeps the lead from oxidizing. The molten lead flows from the blast furnace into holding pots. Lead may be mixed with alloys, including antimony, tin, arsenic, copper and nickel. It is then cast into ingots.

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 Months                      :    Rs.  54.84 cr
Total Capital Investment                               :    Rs.  60.19 Cr
Rate of Return                                                 :    42%
Break Even Point                                             :    31%

INTRODUCTION    
PROPERTIES OF LEAD    
CHEMICAL PROPERTIES    
PHYSICAL PROPERTIES    
MECHANICAL PROPERTIES    
THERMAL PROPERTIES    
TYPES/GRADES    
SPECIFICATIONS OF RECYCLED LEAD    
USES AND APPLICATIONS    
THE FOLLOWING ARE THE APPLICATION AREAS OF LEAD:    
LEAD CAN BE FORMED INTO MANY USEFUL COMPOUNDS.
SOME ARE LISTED BELOW WITH THEIR SPECIFIC APPLICATION AREAS:    
TYPICAL USES    
TYPICAL HISTORICAL USES FOR LEAD INCLUDED:    
TYPICAL CURRENT USES FOR LEAD INCLUDE:    
B.I.S. SPECIFICATION    
MARKET SCENARIO    
INTERNAL DEMAND    
APPARENT CONSUMPTION    
FUTURE DEMAND    
DEMAND FORECAST BASED ON CAGR AND GDP GROWTH    
DEMAND PROJECTIONS BASED ON SECTOR WISE GROWTH    
LEAD INGOTS EXPORT FROM INDIA    
MANUFACTURERS/SUPPLIERS OF LEAD INGOT    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
MAINLY TWO TYPES PROCESS ARE USED WHICH ARE GIVEN BELOW:    
(1) VARTA PROCESS    
(2) MA & CX PROCESS    
BATTERY SCRAPS PREPARATION.
BATTERY BREAKING PROCESS    
BATTERY BREAKING    
AUTOMOTIVE BATTERY BREAKING    
MANUAL    
TUMBLER    
SINK/FLOAT PROCESS    
INDUSTRIAL BATTERY BREAKING    
PASTE DE-SULPHURISATION    
RAW MATERIALS PROCESSING > CHARGE PREPARATION/DRYING    
DRYING    
HANDLING AND TRANSPORT    
BELT CONVEYORS    
POTENTIAL SOURCE OF EXPOSURE:    
SCREW CONVEYORS    
BUCKET ELEVATORS AND DRAG CHAINS/LINES    
SMELTING PROCESS (LEAD REDUCTION)    
SMELTING CAN BE CARRIED OUT IN THE FOLLOWING VESSELS:    
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    
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    80
LEAD INGOT CASTING MACHINE    
INTRODUCTION    
OPERATING PRINCIPLE    
MODEL OF INGOT CASTING MACHINE:
ADVANTAGES:    
LEAD REFINING FURNACE    
LEAD ALLOYING    
ADVANTAGES:    
BLAST FURNACE    
GBF BLAST FURNACES:    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF LEAD ACID BATTERY SCRAP    
SODA ASH    
COKE    
IRON    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF LEAD SMELTING PLANT    
EOT CRANE    
DG 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