Industry Overview
Lead is a chemical element represented by the symbol Pb and having an atomic number of 82. It belongs to group 14 of the periodic table and has been used for centuries. Lead is commonly found in ores associated with silver, zinc, and copper. It is a soft, dense, ductile, malleable, and corrosion-resistant metal. When freshly cut, lead has a bluish-white appearance, but exposure to air causes its surface to tarnish to a dull gray.
Because lead is toxic, its handling, processing, recycling, and disposal require careful controls to minimize human exposure and environmental impact. The project report covers the chemical, physical, mechanical, and thermal properties of lead, along with its types, grades, specifications, uses, historical and current applications, and relevant B.I.S. specifications.
The report also describes recycled-lead manufacturing, including battery scrap preparation, battery breaking and separation, paste de-sulphurisation, smelting, refining, casting, lead alloying, and pollution-control systems. Major equipment discussed includes battery cutting and breaking systems, rotary and blast furnaces, lead refining furnaces, ingot casting machines, dust collectors, cyclones, cooling towers, bag houses, wet scrubbers, and chimneys. It further addresses plant layout, suppliers, market position, pollution management, and project economics.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 50 MT/Day |
| Land & Building (20,000 sq.mt.) | Rs. 13.34 Cr |
| Plant & Machinery | Rs. 3.82 Cr |
| Working Capital for 2 Months | Rs. 46.35 Cr |
| Total Capital Investment | Rs. 63.88 Cr |
| Rate of Return | 49% |
| Break Even Point | 31% |
Content Index
- INTRODUCTION
- CHEMICAL PROPERTIES
- PHYSICAL PROPERTIES
- MECHANICAL PROPERTIES
- THERMAL PROPERTIES
- TYPES / GRADES
- SPECIFICATIONS OF RECYCLED LEAD
- USES AND APPLICATION
- TYPICAL USES
- TYPICAL HISTORICAL USES FOR LEAD INCLUDED:
- TYPICAL CURRENT USES FOR LEAD INCLUDE:
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- MAINLY TWO TYPES PROCESS IS USED WHICH ARE GIVEN BELOW:
- (1) VARTA PROCESS
- (2) MA AND CX PROCESS
- BATTERY SCRAPS PREPARATION.
- BATTERY BREAKING PROCESS
- BATTERY BREAKING
- FIG: HAMMER MILL
- AUTOMOTIVE BATTERY BREAKING
- MANUAL
- TUMBLER
- FIG. 3: ENCLOSED AND EXHAUST VENTILATED TUMBLER AND DUCT WORK
- SINK/FLOAT PROCESS
- FIG. 4: VIEW OF SINK/FLOAT SYSTEM
- FIG. 5: SCREW CONVEYORS REMOVING LEAD BEARING MATERIAL FROM A TANK IN THE SINK/FLOAT PROCESS
- INDUSTRIAL BATTERY BREAKING
- PASTE DE-SULPHURISATION
- DRYING
- HANDLING AND TRANSPORT
- BELT CONVEYORS
- POTENTIAL SOURCE OF EXPOSURE:
- SCREW CONVEYORS
- BUCKET ELEVATORS AND DRAG CHAINS/LINES
- SMELTING PROCESS (LEAD REDUCTION)
- FIG: ROTARY DRUM FURNACE
- SHAFT FURNACE
- 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
- FURNACE:
- THE FOLLOWING REACTIONS CAN TAKE PLACE;-
- 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
- LEAD INGOT CASTING MACHINE
- INTRODUCTION
- OPERATING PRINCIPLE
- MODEL OF INGOT CASTING MACHINE:
- ADVANTAGES:
- LEAD REFINING FURNACE
- OPERATING PRINCIPLE
- LEAD ALLOYING
- ADVANTAGES:
- BLAST FURNACE
- GBF BLAST FURNACES:
- MARKET POSITION
- IMPACT OF COVID-19 ON RECYCLED LEAD MARKET
- SOME OF THE KEY PLAYERS IN THE RECYCLED LEAD MARKET ARE-
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF LEAD INGOT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF LEAD ACID BATTERY SCRAP
- SUPPLIERS OF SODA ASH
- SUPPLIERS OF COKE
- SUPPLIERS OF IRON
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF LEAD RECYCLING PLANT
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMER
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Lead recycling is the process of recovering usable lead from lead-containing scrap and converting it into refined or alloyed products.
In the project report, the principal feedstock is lead-acid battery scrap. The process can include scrap preparation, battery breaking and component separation, paste de-sulphurisation, drying, smelting, refining, alloying, and casting. Appropriate material handling and pollution-control systems are essential because lead and its compounds are hazardous and must be managed to minimize occupational and environmental exposure.
Lead-acid battery scrap is a major raw material used in recycled lead production.
The report specifically includes suppliers of lead-acid battery scrap among the raw-material supply categories. Battery scrap must be prepared and broken so that lead-bearing material and other components can be separated before subsequent treatment. Depending on the selected process, materials such as soda ash, coke, and iron may also be involved. Safe storage, handling, transportation, and processing are particularly important because battery scrap can contain lead compounds and other hazardous materials.
The main stages are battery scrap preparation, breaking and separation, paste treatment, smelting, refining, and casting.
The report describes several operations used to recover lead from battery scrap. These include battery breaking systems, sink/float separation, paste de-sulphurisation, drying, material handling, lead reduction in furnaces, pyrometallurgical refining, drossing, lead alloying, and casting into ingots. The exact process configuration depends on the selected technology and plant design. Pollution-control equipment is integrated with furnace and material-handling operations to control emissions and manage process residues.
Pollution control is essential because lead processing can generate dust, fumes, and other emissions that require controlled collection and treatment.
The report outlines a pollution-control system incorporating equipment such as settling chambers, gravity chambers, cyclones, bag houses, cooling towers, wet scrubbers, and stacks. Dust collection and controlled material handling help reduce potential exposure. A comprehensive pollution management plan also addresses waste and emissions generated during processing. The selection, operation, and maintenance of control equipment should be aligned with applicable environmental and occupational requirements.
A recycled lead plant requires equipment for battery processing, smelting, refining, casting, material handling, and pollution control.
The report identifies battery cutting machines, battery breaking and separation systems, battery hydro separation systems, rotary furnaces, furnace charging machines, lead refining furnaces, blast furnaces, and lead ingot casting machines. Supporting systems include conveyors, cranes, transformers, electrical panels, cooling towers, air compressors, weighing equipment, and water-treatment equipment. Pollution-control equipment includes dust collectors, cyclones, spark arresters, bag houses, wet scrubbers, and chimneys.
Lead is valued industrially for its density, malleability, ductility, corrosion resistance, and other physical and chemical characteristics.
The report provides detailed chemical, physical, mechanical, and thermal property data. It identifies lead as a soft and dense metal with a melting point of 327°C and a boiling point of 1755°C. It also provides data for tensile strength, Poisson’s ratio, modulus of elasticity, shear modulus, hardness, thermal expansion, and thermal conductivity. These properties help determine how lead is handled, processed, refined, alloyed, cast, and used in industrial applications.
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