Detailed Project Report on RECYCLE OF LEAD ACID BATTERY (LEAD REFINING PROCESS)

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RECYCLE OF LEAD ACID BATTERY

(LEAD REFINING PROCESS)

[CODE NO.3822]

About 60% of lead produced world-wide is derived from ore. Lead ore is minedin many countries around the world, though three quarters of world output comesfrom only six countries: China, Australia, USA, Peru, Canada and Mexico. Smallamounts are mined in several countries in Europe, with the biggest producer being Sweden. Total production has been at a similar level since the 1970s; new mines open or are expanded to replace old mines. (Note: all these mines contain at least two metals (also zinc, sometimes silver, gold and copper) so lead extraction is not the only reason for the mining.).

Lead is naturally sourced from an ore called Galena. However the biggest ore of Lead Available above the Surface of the Earth are various types of Lead Scraps. Lead Acid Battery Scrap being the primary source of Lead Scrap. There are other sources of Lead Scrap as well but any Lead Recycling plant can be confidently dependent on Lead Acid Battery Scrap as its continuous and consistent source of Raw Material.

Lead is the 4th most widely used Metal on earth.Lead has highest rate of recycling among all Ferrous & Non-Ferrous Metals.Lead is the only metal on earth which retains its 100% Chemical & Physical properties, irrespective of any number of recycling.Worldwide production of recycled Lead is now about 3 times more than producing Prime Lead.

Lead Acid Batteries Come fit with any vehicle and have a fixed life. After their usage, the batteries are collected by the Dealer who is fitting a new battery in the vehicle. For the returned old battery the dealer of course considers a discount on the new battery. This way the Scrap batteries are sourced and the channelized to various scrap dealers and through them to Lead recycling Plants. This way the Scrap Battery finds its way to be recycled.

Recycling by definition is the reuse of materials, either pre-consumer or post-consumer, that would ordinarily be considered waste. Recycling helps lessen the amount of waste that goes into landfills, helps reduce the amount of toxic chemicals absorbed into the earth and, in some cases, significantly reduces manufacturing costs and energy consumption.

Battery Recycling is good for the Earth and good for future generations. Battery Recycling is the act of processing used or abandoned Batteries, which would otherwise be considered waste and harmful to our environment. Many communities have curbside Battery Recycling services to help out and there are Battery Recycling centers all across the country where Spent Battery can be brought. Often times Battery Recycling centers pay you for dropping Spent Battery off, so it’s a win-win situation.

Lead can end up in water and soils via corrosion of leaded pipelines in water transporting procedure and through corrosion of leaded paints. It cannot be broken down; it can only be converted to other forms.

Lead accumulates in the bodies of water organisms and soil organisms. These will experience health effects from lead poisoning. Health effects on shellfish can take place even when only very small concentrations of lead are present. Body functions of phytoplankton can be disturbed when lead interferes. Phytoplankton is an important source of oxygen production in seas and many larger sea-animals consume it. That is why we now start to wonder whether lead pollution can influence worldwide balances.

Several Battery Recycling Plants are end point of this supply chain. These Factories Break these batteries and Extract Lead bearing material which is then fed in to the Smelting Furnaces. This Lead Bearing Material is a mix of Lead and Lead Oxide. This mixture is smelted in Smelting Furnaces to Produce Cure Lead.

This crude Lead is later refined to a purity of 99.98%. This Lead Produced will now find its way towards a Lead Acid Battery Manufacturing company. The loop is closed here and the cycle begins again.

Lead Acid Batteries are recyclable due to the very nature of Lead. Lead can be recycled almost any number of times. Of course there are process losses but this recyclability of Lead has brought environmental and business sustainability to the Lead Acid battery Industry. Lead Acid Batteries have been irreplaceable for past several years due to this very important factor. Lithium Ion batteries fail miserably in the recyclability factor. Currently the process is not profitable for Entrepreneurs Individually and also the process is too complex due to the complex chemistry of the Lithium Ion Batteries.

Lead Acid Battery Recycling Plant / Battery Recycling Plant Owners should be responsible enough to know that Lead is toxic and should can cause harm to the environment / people if not handled properly. They should select the best of Equipment to make sure that profits are made but sustainably and responsibly.

The battery contains 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 1000?C lead and slag is tapped separately. Refining is done by lowering the temperature thereby decreasing the solubility of impurities.

COST ESTIMATION

Plant Capacity 40 MT/Day

Land & Building (1000 sq.mt.) Rs. 62 Lac

Plant & Machinery Rs. 1.25 Cr

Working Capital for 1 Month Rs. 11.43 Cr

Total Capital Investment Rs. 13.47 Cr

Rate of Return 92%

Break Even Point 21%

INTRODUCTION

FACTORS INFLUENCING HIGH COLLECTION RATES OF LEAD ARE:

RECYCLING PROCESSES

LOCATION FOR PLANT

SOME AMAZING BENEFITS OF BATTERY RECYCLING

REDUCTION IN WASTE SENT TO LANDFILLS AND TURNING THEM INTO

NEW PRODUCTS

COMPOSITION OF REFINED LEAD / PURE LEAD

PURE LEAD SPECIFICATION

COMPOSITION OF REFINED LEAD / PURE LEAD

AVAILABLE BATTERY TYPES

A) ACID VS. ALKALINE

WET VS. DRY

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