Industry Overview
Lead-acid batteries are among the most commonly used energy storage technologies in solar power systems. These electrochemical devices convert chemical energy into electrical energy and deliver direct current (DC) electricity. Their established technology and wide range of applications have made them important components in automotive systems, UPS and inverter systems, traction equipment, electrical substations, telecommunications, and solar photovoltaic installations.
Lead-acid batteries are primarily classified into two types: flooded or vented batteries and sealed lead-acid batteries. Their construction generally involves lead-based plates, an electrolyte, separators, and a suitable container. Battery performance depends on the materials used, plate design, manufacturing methods, formation processes, assembly procedures, and quality-control practices.
The manufacture of lead-acid batteries involves several operations, including grid casting, lead oxide production, paste preparation, plate pasting, curing, formation, assembly, testing, and finishing. Recycling is another important part of the industry, involving the collection, transportation, storage, breaking, lead reduction, and refining of used batteries. These recycling operations require appropriate environmental safeguards to control potential contamination from lead and other process materials.
Establishing a lead-acid battery manufacturing project requires consideration of plant layout, machinery, raw material availability, utilities, material handling, pollution-control equipment, and effluent treatment facilities. Quality assurance throughout production helps ensure battery reliability, safety, and compliance with applicable specifications.
Cost Estimation
| Particulars | Project Details |
|---|---|
| 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% |
Content Index
- 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
- 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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