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
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