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
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